AP 240

PNEU TYRED ROLLER

CUMMINS QSB3.3-C99
EU Stage IIIA / U.S. EPA Tier 3

OPERATING MANUAL
EDITION 01/2021 EN
Product Identification Number 3001576 -
 ES / EU Prohlášení o shodě
(Původní ES/EU prohlášení o shodě / Original EC/EU Declaration of conformity / Ursprüngliche EG-/EU-Konformitätserklärung )

EC / EU Declaration of conformity / EG-/EU-Konformitätserklärung

(Překlad původního ES/EU prohlášení o shodě /Translation original EC/EU Declaration of conformity / Übersetzung der ursprünglichen EG-/EU-Konformitätserklärung )
Originální ES/EU prohlášení o shodě je dodané s dokumenty během expedice stroje. / The original EC/EU Declaration of Conformity is supplied with documents during
expedition of machine. / Das Original der EG-/EU-Konformitätserklärung wird mit den Unterlagen während des Versands der Maschine mitgeliefert.

Výrobce / Manufacturer / Hersteller: Ammann Czech Republic a.s.

Adresa / Address / Adresse: Náchodská 145, CZ-549 01 Nové Město nad Metují, Czech Republic
IČ / Identification Number / Ident.-Nr: 000 08 753
Jméno a adresa osoby pověřené sestavením technické Ing. Radek Ostrý
dokumentace podle 2006/42/ES a jméno a adresa osoby, která Ammann Czech Republic a.s.
uchovává technickou dokumentaci podle 2000/14/ES / Name and Náchodská 145, CZ-549 01 Nové Město nad Metují, Czech Republic
address of the person authorised to compile the technical file according
to 2006/42/EC and name and address of the person, who keeps the
technical documentation according to 2000/14/EC / Name und Adresse
der mit der Zusammenstellung der technischen Dokumentation
beauftragten Person gemäß 2006/42/EG und Name und Adresse der mit
der Aufbewahrung der technischen Dokumentation beauftragten
Person gemäß 2000/14/EG:

Popis strojního zařízení / Description of the machinery / Beschreibung

der Maschineneinrichtung:
Označení / Designation / Bezeichnung: Pneumatikový válec / Pneu tyred roller / Gummiradwalze

Typ / Type / Typ: AP 240

Verze / Version / Version:
Product Identification Number:
Motor / Engine / Motor: Cummins QSB 3.3-C99, vznětový, jmenovitý výkon (ISO 3046-1): 74,0 kW, jmenovité
otáčky: 2200 min-1 / Cummins QSB 3.3-C99, Diesel, nominal power (ISO 3046-1): 74,0
kW, rated speed: 2200 RPM / Cummins QSB 3.3-C99, Dieselmotor, Nennleistung (ISO
3046-1): 74,0 kW, Nenndrehzahl: 2200 min -1

Prohlašujeme, že strojní zařízení splňuje všechna příslušná
ustanovení uvedených směrnic / We declare, that the machinery fulfils
all the relevant provisions mentioned Directives / Wir erklären, dass die
Maschineneinrichtung sämtliche entsprechenden Bestimmungen
aufgeführter Richtlinien erfüllt:
Harmonizované technické normy a technické normy použité
k posouzení shody / The harmonized technical standards and the
technical standards applied to the conformity assessment /
Harmonisierte technische Normen und für die Beurteilung der
Konformität verwendete Normen:
Strojní zařízení – směrnice 2006/42/ES / Machinery Directive 2006/42/EC /
Maschineneinrichtung – Richtlinie 2006/42/EG
Elektromagnetická kompatibilita – směrnice 2014/30/EU / Electromagnetic
Compatibility Directive 2014/30/EU / Elektromagnetische Kompatibilität – Richtlinie
2014/30/EU
Emise hluku – směrnice 2000/14/ES / Noise Emission Directive 2000/14/EC /
Lärmemissionen – Richtlinie 2000/14/EG
ČSN EN ISO 12100, ČSN EN 500-1+A1, ČSN EN 500-4, ČSN EN ISO 4413,
ČSN EN ISO 4414, ČSN EN 13309

Osoby zúčastněné na posouzení shody / Bodies engaged in the
conformity assessment / An der Konformitätsbeurteilung beteiligte
Personen:
Notifikovaná osoba č. 1016 / Notified Body No.: 1016 / Notifizierte Stelle Nr.: 1016
Státní zkušebna strojů a.s., Třanovského 622/11, 163 04 Praha 6–Řepy, ČR. / The
Government Testing Laboratory of Machines J.S.C., Třanovského 622/11, 163 04
Praha 6–Řepy, Czech Republic / Staatliche Prüfstelle für Maschinen AG,
Třanovského 622/11, 163 04 Praha 6–Řepy, Tschechische Republik.

Použitý postup posouzení shody / To the conformity assessment Na základě směrnice 2000/14/ES příloha VI / Pursuant to the Noise Emission Directive
applied procedure / Verwendetes Vorgehen der 2000/14/EC, Annex VI / Aufgrund der Richtlinie 2000/14/EG, Anlage VI
Konformitätsbeurteilung:
Naměřená hladina akustického výkonu / Measured sound power level LWA = 100 dB
/ Gemessener Schallleistungspegel:
Garantovaná hladina akustického výkonu / Guaranteed sound power LWA = 101 dB
level / Garantierter Schallleistungspegel:

Místo a datum vydání / Place and date of issue / Ort und Datum der Nové Město nad Metují,
Ausgabe:
Osoba zmocněná k podpisu za výrobce / Signed by the person entitled to deal in the name of manufacturer / Zeichnungsberechtigter für den Hersteller:

Jméno / Name / Name: Jiří Sychra

Funkce / Grade / Stelle: Logistics Manager
Podpis / Signature / Unterschrift: CZ / EN / DE
Congratulations on your purchase of an AMMANN road roller. This modern compaction device is characterised by simple operation
and maintenance and is the product of many years of AMMANN experience in the field of road roller engineering. In order to avoid
faults due to improper operation and maintenance we request that you read this operating manual with great care and keep it for later
reference.

With kind regards,

Ammann Czech Republic a.s. | Náchodská 145 | CZ–549 01 Nové Město nad Metují

% + 420 491 476 111 | Fax + 420 491 470 215 | info@ammann.com | www.ammann.com

This instruction manual is a “translation of the original instruction manual” within the meaning of the paragraph 1.7.4.1 of the Directive
of the European parliament and of the Council 2006/42/EC of 17 Mai 2006.

This manual consists of:

I. Specification manual II. Operating instructions III. Maintenance manual

The following explanations serve to familiarise the machinist (operator) with the roller and to support him during handling and main-
tenance. It is therefore absolutely necessary to provide the operator with these instructions and to ensure that he reads them carefully
before using the road roller. This aids training comprehension during the first use of the road roller.
Subsequent faults due to improper operating are avoided.
Adherence to maintenance instructions increases the reliability and lifetime of the machinery. It reduces repair costs and down time.
AMMANN accepts no liability for continued safe functioning of the road roller if it is incorrectly operated and / or operating modes are
employed which represent improper use.
In order to ensure the smooth operation of AMMANN compaction equipment, use for repairs only the original spare parts
supplied by AMMANN.

These instructions must always be kept available on the equipment.

AP 240 1
Preface

Information, specifications, and recommended operation and maintenance instructions contained in this publication are basic and
final information at the time of the printing of this publication. Printer’s errors, technical modifications, and modifications of figures are
reserved. All dimensions and weights are approximate and, therefore, not binding.
Ammann Czech Republic a.s. reserves the right to perform modifications without obligation to inform the machine user. If you identify
any differences between the machine operated by you and the information contained in this publication, contact your local dealer.
Reproduction or copying of any kind is prohibited without the written permission of Ammann Czech Republic a.s.

2 AP 240
 SYMBOLS OF THE SAFETY NOTICES:

The notice warns of a serious risk of personal injury or other personal hazards.

The notice warns of possible damages to the machine or its parts.

The notice warns of the necessity of environmental protection.

! NOTICE !
As used in this operating manual, the terms „right“, „left“, „front“ and „rear“ indicate the sides of the machine
moving forward.

REAR

RIGHT

LEFT

FRONT

37402en

AP 240 3
Content
Content..............................................................................................................................................................4
1. SPECIFICATION MANUAL.......................................................................................................................9
1.1. Basic Data...............................................................................................................................................10
1.2. Dimensional machine drawing.............................................................................................................12
1.3. Technical data........................................................................................................................................15

4 AP 240
 OPERATING MANUAL
2. OPERATION MANUAL...........................................................................................................................21
2.1. Main Safety Measures...........................................................................................................................23
2.1.1. Safety measures during Machine operation.................................................................................................................................................23
2.1.1.1. Compaction Work Commencement................................................................................................................................................................23
2.1.1.2. Work in the dangerous area................................................................................................................................................................................23
2.1.1.3 Ensurance of safety measures by the owner................................................................................................................................................24
2.1.1.4. ROPS............................................................................................................................................................................................................................24
2.1.2. Requirements for qualification of driver........................................................................................................................................................25
2.1.3. Duties of the driver.................................................................................................................................................................................................26
2.1.4. Forbidden activities – safety and guarantee.................................................................................................................................................27
2.1.5. Safety inscriptions and symbols used on the Machine.............................................................................................................................28
2.1.6. Hand signals.............................................................................................................................................................................................................32

2.2. Ecological and hygienic principles.......................................................................................................35

2.2.1. Hygienic principles.................................................................................................................................................................................................35
2.2.2. Ecological principles..............................................................................................................................................................................................35

2.3. Machine preservation and storage......................................................................................................36

2.3.1. Short-term preservation and storage for a period of 1 – 2 months.....................................................................................................36
2.3.2. Preservation and storage for the period over 2 months long................................................................................................................36
2.3.3. Dewaxing and inspection of a supplied machine......................................................................................................................................37

2.4. Machine disposal following its life cycle end......................................................................................38

2.5. Machine Description.............................................................................................................................39
2.6. Controllers & Control Instruments.......................................................................................................40
2.6.1. Power View control ...............................................................................................................................................................................................53

2.7. Machine Control and Usage..................................................................................................................63

2.7.1. Engine starting........................................................................................................................................................................................................64
2.7.2. Travel & Reversation...............................................................................................................................................................................................66
2.7.3. Emergency stop of the Machine.......................................................................................................................................................................69
2.7.4. How to stop the Machine and the engine.....................................................................................................................................................70
2.7.5. Machine parking.....................................................................................................................................................................................................71
2.7.6. Watering and scrapers..........................................................................................................................................................................................72
2.7.7. Additional weighting of the machine.............................................................................................................................................................72
2.7.8. Edge Cutter...............................................................................................................................................................................................................73

2.8. How to transport the Machine..............................................................................................................74

2.8.1. Loading the machine............................................................................................................................................................................................75
2.8.1.1. Loading the machine using a ramp.................................................................................................................................................................75
2.8.1.2. Loading the machine using a crane.................................................................................................................................................................75

2.9. Machine work under heavy conditions...............................................................................................76

2.9.1. Machine towing......................................................................................................................................................................................................76
2.9.2. Machine operation during its running-in period........................................................................................................................................78
2.9.3. Machine operation at low temperatures.......................................................................................................................................................78
2.9.4. Machine work under high temperatures and humidity...........................................................................................................................78
2.9.5. Machine work in high altitudes.........................................................................................................................................................................78
2.9.6. Work of the machine in the dusty environment.........................................................................................................................................78

AP 240 5
Content
3. MAINTENANCE MANUAL.....................................................................................................................81
3.1. Safety standards and other maintenance regulations ......................................................................83
3.1.1. Safety of machine maintenance........................................................................................................................................................................83
3.1.2. Fire precautions during operation media exchanges...............................................................................................................................83
3.1.3. Ecological and hygienic standards...................................................................................................................................................................84

3.2. Media Specification...............................................................................................................................85

3.2.1. Engine Oil..................................................................................................................................................................................................................85
3.2.2. Fuel...............................................................................................................................................................................................................................86
3.2.3. Coolant ......................................................................................................................................................................................................................87
3.2.4. Hydraulic Oil ............................................................................................................................................................................................................87
3.2.5. Oil – epicyclic transmission incl. torque converter.....................................................................................................................................88
3.2.6. Gear Oil ......................................................................................................................................................................................................................88
3.2.7. Brake Fluid.................................................................................................................................................................................................................88
3.2.8. Lube Grease..............................................................................................................................................................................................................88
3.2.9. Windscreen Sprayer Liquid.................................................................................................................................................................................88
3.2.10. Air-conditioning filling..........................................................................................................................................................................................88

3.3. Media......................................................................................................................................................89
3.4. Lubrication and Maintenance Chart....................................................................................................90
3.5. Lubrication and Service Plan ...............................................................................................................93
3.6. Lubrication and Maintenance Operations...........................................................................................94

Every 20 hours of operation (daily)......................................................................................................95

3.6.1. Engine oil level check............................................................................................................................................................................................95
3.6.2. Engine cooling liquid level check.....................................................................................................................................................................96
3.6.3. Crankcase breather tube......................................................................................................................................................................................96
3.6.4. Fan condition check and engine belt check.................................................................................................................................................97
3.6.5. Air filter dust valve check.....................................................................................................................................................................................98
3.6.6. Hydraulic oil level check.......................................................................................................................................................................................98
3.6.7. Brake fluid check.....................................................................................................................................................................................................99
3.6.8. Water tank refill..................................................................................................................................................................................................... 100
3.6.9. Water separator cleaning.................................................................................................................................................................................. 100
3.6.10. Oil in the gearbox check.................................................................................................................................................................................... 101
3.6.11. Warning and control devices check.............................................................................................................................................................. 102
3.6.12. Check of the front axle....................................................................................................................................................................................... 104

Every 100 hours of operation (weekly)..............................................................................................105

3.6.13. Tyre pressure check............................................................................................................................................................................................. 105
3.6.14. Check of the oil level in the front axle hydraulic cylinders................................................................................................................... 106

Every 250 hours of operation (3 months)..........................................................................................107

3.6.15. Engine oil change................................................................................................................................................................................................ 107
3.6.16. Engine induction manifold and air filter sensor check........................................................................................................................... 109
3.6.17. Battery check......................................................................................................................................................................................................... 111
3.6.18. Machine lubrication............................................................................................................................................................................................ 113

6 AP 240
 OPERATING MANUAL
Every 500 hours of operation (6 months)..........................................................................................115
3.6.19. Fuel filters replacement..................................................................................................................................................................................... 115
3.6.20. Engine cooling liquid check............................................................................................................................................................................. 117
3.6.21. Gearbox oil filter replacement........................................................................................................................................................................ 118
3.6.22. Oil in differential and oil in rear axle check................................................................................................................................................ 119
3.6.23. Wiring check.......................................................................................................................................................................................................... 119
3.6.24. Checking the air-conditioning coolant level............................................................................................................................................. 120
3.6.25. Air filter elements replacement...................................................................................................................................................................... 121
3.6.26. Filter of the cab ventilation replacement................................................................................................................................................... 123
3.6.27. Air filter of the air conditioning system replacement............................................................................................................................. 124

Every 1000 hours of operation (1 year).............................................................................................125

3.6.28. Brake shoes adjustment.................................................................................................................................................................................... 125
3.6.29. KM nuts tightening check and front wheels lubrication....................................................................................................................... 128
3.6.30. Hydraulic accumulator check.......................................................................................................................................................................... 129
3.6.31. Engine belt check................................................................................................................................................................................................ 130
3.6.32. Inspection of the air-conditioning compressor and air-conditioning belt..................................................................................... 131
3.6.33. Gearbox oil change............................................................................................................................................................................................. 132
3.6.34. Oil in differential change................................................................................................................................................................................... 133
3.6.35. Air drier replacement......................................................................................................................................................................................... 134

Every 2000 hours of operation (2 years)............................................................................................135

3.6.36. Valve clearance adjustment............................................................................................................................................................................. 135
3.6.37. Oil in rear axle change........................................................................................................................................................................................ 135
3.6.38. Hydraulic oil and filter change........................................................................................................................................................................ 137
3.6.39. Oil in front axle hydraulic cylinders change............................................................................................................................................... 141
3.6.40. Brake fluid change............................................................................................................................................................................................... 142
3.6.41. Engine cooling liquid change......................................................................................................................................................................... 144
3.6.42. Compressor check............................................................................................................................................................................................... 146
3.6.43. Air conditioning system check........................................................................................................................................................................ 147

Maintenance if required......................................................................................................................148
3.6.44. Water from separator draining........................................................................................................................................................................ 148
3.6.45. Fuel system venting............................................................................................................................................................................................ 149
3.6.46. Coolers cleaning................................................................................................................................................................................................... 150
3.6.47. Refilling the oil level in the front axle hydraulic cylinders.................................................................................................................... 151
3.6.48. Sprinkling filter cleaning................................................................................................................................................................................... 153
3.6.49. Brush scrapers cleaning..................................................................................................................................................................................... 153
3.6.50. Machine cleaning................................................................................................................................................................................................ 154
3.6.51. Check of wheel nuts for tightening............................................................................................................................................................... 155
3.6.52. Air collector inspection...................................................................................................................................................................................... 155
3.6.53. Charging of the battery..................................................................................................................................................................................... 156
3.6.54. Screw connection tightening check............................................................................................................................................................. 157

3.7. Defects..................................................................................................................................................159
3.8. Annexes................................................................................................................................................160
3.8.1. Wiring Diagram..................................................................................................................................................................................................... 160
3.8.2. Hydraulics Diagram............................................................................................................................................................................................. 166
3.8.3. Air Distribution..................................................................................................................................................................................................... 168
3.8.4. Table of spare parts............................................................................................................................................................................................. 170

AP 240 7
8 AP 240
 SPECIFICATION MANUAL

1. SPECIFICATION MANUAL

AP 240
(Cummins Tier 3)

AP 240 9
1.1. Basic Data
Machine description
Please fill in the following data:
Pneu tyred roller with a rigid frame with a front steerable iso- (see Pin label, Label of the CUMMINS engine)
static axle and rear drive axle. Each axle is mounted with four
smooth tyres.
Type of machine

Machine application
................................................................................................................
The roller is intended for medium and large-sized compaction Product Identification Number
works in transport construction (roads and motorways, railways,
airfields) and building construction (industrial zones, etc.).
The roller is suitable for compacting the asphalt mixtures up to a ................................................................................................................
layer thickness (after compaction) of 120 mm, hydraulically con- Production year
solidated mixtures up to a layer thickness of 150 mm, loam and
clay soils up to a layer thickness of 150 mm, mixed soils up to a
layer thickness of 200 mm, and sand and gravel materials up to ................................................................................................................
a layer thickness of 250 mm. Type of engine
The roller is not suitable for the compaction of rockfill.
The machines are designed for operation in arid, temperate and ................................................................................................................
cold climates according to EN 60721-2-1:2014 with a limited
temperature range from -15 °C (5 °F) to +45 °C (113 °F) and a Serial number of the engine
maximum absolute humidity of 25 g.m-3.
The standard type of the machine is not intended for road traf- ................................................................................................................
fic. For more information, please contact your dealer.

Please refer to the data in the table below always when ap-
proaching the dealer or the manufacturer.

10 AP 240
 SPECIFICATION MANUAL
The machine that complies with the requirements as to health 4145

protection and safety is identified with a name plate with CE

marking.
1
AMMANN CZECH REPUBLIC a.s.
549 01 NOVÉ MĚSTO NAD METUJÍ, Náchodská 145
CZECH REPUBLIC

1. Name – always mentioned only in the English version 8

2. Type 2 DESIGNATION

3. Product identification number

TYPE

9
VERSION

4. Rated power
3 PRODUCT IDENTIFICATION NUMBER

5. Operating weight 4 NOMINAL POWER ENGINE EMISSIONS 10

6. Maximum weight
11
OPERATING MASS FRONT AXLE LOAD

7. Shipping weight 5 MAXIMUM MASS REAR AXLE LOAD

8. Version
6
SHIPPING MASS YEAR OF CONSTRUCTION
12
9. Engine emissions MODEL YEAR

13
10.Front axle load 7
4145
MADE IN CZECH REPUBLIC

11.Rear axle load

12.Year of manufacture
13.Model year

Name plate location 2

1 - Name plate
2 - Machine frame number

AP001

Engine name plate location

374112

AP 240 11
1.2. Dimensional machine drawing

H1
G*
G

374002

A G G* H H1 L L1 W W1 W2

mm 3800 340 260 3110 2450 5020 5780 1986 2100 2310

(in) (149.6) (13.4) (10.2) (122.4) (96.5) (197.6) (227.6) (78.2) (82.7) (90.9)

12 AP 240
 SPECIFICATION MANUAL

W H
W1

374001

A G G* H H1 L L1 W W1 W2

mm 3800 340 260 3110 2450 5020 5780 1986 2100 2310

(in) (149.6) (13.4) (10.2) (122.4) (96.5) (197.6) (227.6) (78.2) (82.7) (90.9)

AP 240 13
1.2. Dimensional machine drawing

L1L2

W2
374016

A G G* H H1 L L1 W W1 W2

mm 3800 340 260 3110 2450 5020 5780 1986 2100 2310

(in) (149.6) (13.4) (10.2) (122.4) (96.5) (197.6) (227.6) (78.2) (82.7) (90.9)

14 AP 240
1.3. Technical data SPECIFICATION MANUAL

AP 240
EU Stage IIIA / U.S. EPA Tier 3
Weight
Operating weight of EN 500-1+A1 (CECE) with cab, ROPS kg (lb) 9590 (21140)
Operating weight of EN 500-1+A1 (CECE) with cab kg (lb) 9290 (20480)
Operating weight of EN 500-1+A1 (CECE) with platform, rail kg (lb) 9060 (19970)
Weight of half fluid capacities kg (lb) 330 (730)
Operating weight of ISO 6016 with cab, ROPS kg (lb) 9690 (21360)
Maximum weight with the cab, ROPS, accessories, weighing kg (lb) 24000 (52910)
Maximum permitted weight according to ROPS kg (lb) 24000 (52910)
Weight of empty ballast tanks kg (lb) 1100 (2430)
Balance weight 6 t kg (lb) 6000 (13230)
Weight of ballast tanks filled with concrete kg (lb) 2800 (6170)
Weight of ballast in frame – water kg (lb) 3000 (6610)
Weight of ballast in frame – sand kg (lb) 4500 (9920)
Weight of ballast in the frame – scrap up to the total machine
kg (lb) 24000 (52910)
weight
Cab weight kg (lb) 280 (620)
Weight of ROPS kg (lb) 300 (660)
Weight of ROPS/FOPS (CNH design) kg (lb) 530 (1170)
Weight of sheet roof on ROPS kg (lb) 50 (110)
Weight of canopy kg (lb) 50 (110)
Weight of canopy posts (version without ROPS) kg (lb) 60 (130)
Weight of wheel insulation kg (lb) 120 (260)
Weight of Ammann edge cutter kg (lb) 150 (330)
Driving characteristics
Number of speeds - 3
Maximum transport speed km/h (MPH) 0-19 (0-11.8)
Working speed 1 km/h (MPH) 0-5 (0-3.1)
Working speed 2 km/h (MPH) 0-11 (0-6.8)
Working speed 3 km/h (MPH) 0-19 (0-11.8)
Climbing ability % 25
Lateral static stability % 25
Turning radius inner (edge) left mm (in) 6180 (243.3)
Turning radius inner (edge) right mm (in) 6065 (238.8)
Turning radius outer (contour) left mm (in) 9960 (392.1)
Turning radius outer (contour) right mm (in) 8735 (343.9)
Type of drive - Hydrodynamic
Type of gearbox - Three-stage reversing
Number of driving axles - 1
Number of driven wheels - 4
Oscillation angle ° 3
Angle of steering ° 32
Steering
Type of steering - Two-point suspension
Steering control - Hydraulic power steering
Linear hydraulic motors - 1

AP 240 15
1.3. Technical Data

AP 240
EU Stage IIIA / U.S. EPA Tier 3
Engine
Manufacturer - Cummins
Type - QSB3.3-C99
Power according to ISO 3046-1 kW (HP) 74 (99)
Number of cylinders - 4
Cylinder capacity cm³ (cu in) 3300 (201)
Nominal speed min¯¹ (RPM) 2200
Maximum torque Nm (ft lb)/rpm 415 (306)/1600
Average fuel consumption l/h (gal US/h) 7.8 (2.1)
Engines complies with emission regulations - EU Stage IIIA, U.S. EPA Tier 3
Cooling system of engine - Liquid
Maximum permitted speed during engine braking min¯¹ (RPM) 3250
Axle
Maximum tyre pressure MPa (PSI) 0.75 (108.8)
Minimum tyre pressure MPa (PSI) 0.2 (29)
Pattern of tyres - COM HL.
Number of tyres - 8
Number of front wheels - 4
Number of rear wheels - 4
Size of tyres - 11.00x20´´
Type of tyres - Tube Type
Brakes
Operating - drum
Parking - Mechanical disc
Emergency - Mechanical disc
Watering
Type of watering - Pressure
Number of pumps - 1
Fluid capacities
Fuel l (gal US) 250 (66)
Water for tyre watering l (gal US) 460 (121.5)
Engine (oil filling) l (gal US) 7 (1.8)
Cooling system l (gal US) 20.5 (5.4)
Gearbox oil l (gal US) 21.5 (5.7)
Differential oil l (gal US) 6 (1.6)
Oil in front axle disengaging l (gal US) 3.5 (0.9)
End gear oil l (gal US) 2x5.2 (2x1.37)
Hydraulic system oil l (gal US) 22 (5.8)
Brake fluid l (gal US) 1.75 (0.5)
Wiring
Voltage V 12
Battery capacity Ah 135

16 AP 240
 SPECIFICATION MANUAL

AP 240
EU Stage IIIA / U.S. EPA Tier 3
Noise and vibration emissions
Measured sound power level A, LpA at the operator's position (cab) * dB 81
Uncertainty KpA * dB 2
Guaranteed sound power level A, LWA ** dB 101
Declared highest weighted effective value of vibration acceleration
m/s2 (ft/s2) <0.5 (<1.6)
transmitted to the whole body (cab) ***
Declared total value of vibration acceleration transmitted to hands
m/s2 (ft/s2) <2.5 (<8.2)
(cab) ***
* measured according the EN 500-4
** measured according the DIRECTIVE 2000/14/EC
*** measured according the EN 1032+A1 on the gravel base under the vibration travel)

Optional equipment
Cab with ventilation and heating
ROPS protection*
ROPS canopy (mounted to ROPS)
Cab FOPS protection (mounted to ROPS)
Air conditioning
Radio preparation (box, 2 repro, antenna) (cab version only)
Radio, CD, MP3 (cab version only)
Waterproofed Frame
Towing hinge front
Thermal aprons
Edge cutter
Ammann Traction System / Diff lock
4 + 4 tyres MITAS radial instead of standard ones
4 + 4 tyres Dunlop radial instead of standard ones
4 + 4 tyres Michelin radial instead of standard ones
Spare part wheel with smooth diagonal tyre
Ballast 2.800 kg - Concrete
Ballast 6.000 kg - Steel
Ballast (metal into frame) per 1 ton
Fan safety screen
Warning beacon (rotating warning light)
Back-up alarm
Chock blocs
Mirror for front wheel
Cocoa scrapers instead of standard ones
Special colour ral up to 2 colors
Special paint schema
Fire extinguisher
First service kit for the first 500 h (engine filters, air filters)
Toolkit
Wheel spanner
Engine pre-filter
Set of documentation - printed hardcopy

* Compulsory equipment for CE

AP 240 17
 Notes

18 AP 240
 SPECIFICATION MANUAL

Notes

AP 240 19
20 AP 240
 OPERATION MANUAL

2. OPERATION MANUAL

AP 240
(Cummins Tier 3)

AP 240 21
22 AP 240
2.1. Main Safety Measures OPERATION MANUAL
2.1.1. Safety measures during Machine 2.1.1.2. Work in the dangerous area
operation
Any damage of engineering technical services must be imme-
Safety measures stated in individual sections of Technical Docu- diately communicated to their owner, and at the same time the
mentation supplied with the Machine shall be added with the precautions preventing entry of unauthorized persons to the
safety measures in force in the country the Machine is used at endangered area must be carried out.
a work site, and this with regard to work organization, working
process and the personnel.
The workman must not work alone on such working place
where there is not any another workman in view or within call-
ing distance that if necessary would be able to provide help or
2.1.1.1. Compaction Work Commencement
to call for help in case the efficient form of control or connection
is not ensured.
Construction work supplier (Machine operator) is liable to give
such instructions for driver and maintenance personnel which
will include the requirements to secure job safety during Ma-
chine operation.
• Construction work supplier must check and mark the fol-
lowing:
- Utility lines
- Underground areas (direction, depth)
- Toxic material seepage and escape
- Soil bearing capacity, travel plane slope
- Other barriers incl. their removal
He/she shall make Machine driver who will carry out the
ground work, familiar with such condition.

• He/she shall set forth the technological procedure part of

which is the work process for given labour activity, and such
technological procedure will inter alia include:
- Precautions during work under extraordinary conditions
(work within protection zones, in extreme slopes, etc.)
- Precautions for the sake of natural disaster hazard
- Requirements to carry out work while adhering to work
safety principles
- Technical and organizational measures to provide for
safety of employees, workplace and environment
He/she must make Machine driver evidently familiar with
the technological procedure!

AP 240 23
2.1. Main Safety Measures
2.1.1.3 Ensurance of safety measures by the 2.1.1.4. ROPS
owner
The following precautions shall be observed while the protec-
• The owner must ensure that the machine is operated only tion frame ROPS is used:
in such conditions and only for such purposes to which • The machine frame must not be damaged (broken, bent,
the machine is technically capable according to conditions etc.) in the place of connection.
specified by the manufacturer and relevant standards.
• The ROPS frame itself must not show the marks from corro-
• He must ensure that the roller is used only in such manner sion, damage through cracks or splits.
and on such working places without a danger to damage
• ROPS frame must not be loose during the machine opera-
the close structures, sections, etc.
tion.
• He must ensure a regular inspection of operation and tech-
• All bolted connections must meet the specifications require-
nical conditions, regular maintenance of the machine in
ments and must be tightened to the moment specified.
intervals specified in the manuals for greasing and mainte-
nance work. In case the technical condition of the machine • Bolts and nuts must not be damaged, distorted and they
does not meet the requirements to such extent it endangers must not show the marks from corrosion.
safety of operation, people and property or it causes a dam- • None additional modifications can be carried out on the
age and impairment to the environment, the machine must ROPS frame without the approval of the manufacturer be-
be put out of service until the defects are removed. cause they can result in decrease of its strength (e.g. open-
• He must specify who is allowed to carry out operation, main- ings, welding, etc.).
tenance and repairs of the machine as well as what activities • Weight of the machine with the protective frame must not
can be carried out during the operation, maintenance and exceed the permitted weight for which ROPS was approved.
repair of the machine.
• The person (driver) who drives the machine and each per-
son carrying out maintenance and repair of the machine
must be acquainted with instructions specified in the opera-
tion manual of the machine.
• He must ensure that ”Operation manual of the machine” and
operational book are kept on specified place to be at dis-
posal for the driver all the time.
• He must assign a workman for permanent supervision over
the machine work during its operation on public roads and
especially he is obliged to issue instructions to ensure safety
of works.
• He must ensure that dangerous substances (such as fuel,
oils, coolant, break fluid, etc. must be removed from places
of leakage according to their nature to prevent from their
adverse impact to the environment, safety of operation and
health of people.

24 AP 240
 OPERATION MANUAL
2.1.2. Requirements for qualification of driver

• Only a driver trained to ISO 7130 and other local and inter-
national regulations and standards designed for drivers of
this class, may operate the Roller.
• Only a person learning to drive under a direct and constant
supervision by a professional lector or trainer in order to get
a preliminary practice, may drive the Machine with no cer-
tificate of competency, with the approval by Machine Op-
erator.
• Holder of the competency (licence) will be liable to duly
keep the licence, and submit it, as requested, to the control
authorities.
• Holder of the competency shall not make any entries,
changes or corrections in the licence.
• Holder shall report immediately his/her licence loss to the
one who issued such licence.
• Person mentally competent and physically fit person, over
18 years old may drive the Roller individually if:
a) Authorized by Machine manufacturer, for the assembly
work, testing and demonstrate the Machine, or eventu-
ally for training the drivers whereas he/she must have
been made familiar with the work safety regulations ef-
fective in the workplace;
or
b) Assigned by construction work supplier to operate (car-
ry out maintenance), trained and drilled with conclusive
evidence, or eventually owning professional competen-
cy to operate and drive under special regulations (ma-
chinist certificate, or others).
• Machine driver shall be trained min. 1x every 2 years and
examined in regulations to provide for occupational safety.

AP 240 25
2.1. Main Safety Measures
2.1.3. Duties of the driver
• Before Machine operation starts the driver shall be liable to
get familiar with the instructions given in the documenta-
tion supplied together with the Machine, with the safety
measures in particular, and observe these thoroughly. This
applies also to the personnel in charge of maintenance, ad-
justments and repairs of the Machine.
• Do not drive the Roller unless fully made familiar with all
the Machine’s functions, working elements and operation
elements, and until knowing exactly how to control the Ma-
chine.
• Follow the safety symbols placed on the Machine and keep
these in legible condition.
• Before work is started, get familiar with the work site en-
vironment, i.e. with any barriers, slopes, utility line system,
necessary types of workplace protection with respect to the
environment (noise, vibrations, etc.).
• When you find out any hazard to health or life of persons,
property hazard, failure, or upon technology equipment ac-
cident, or when finding any symptoms of such hazards in
course of operation, then the driver, unless able to eliminate
such hazard by himself/herself, must stop the work and se-
cure the machine against any undesirable start; please at-
tach “MACHINE REPAIR” warning sign onto steering wheel
as depicted in Section called “Safety signs used on the ma-
chine“, report this to the person in charge, and if possible,
notify all persons exposed to such danger.
• Before starting Machine operation, get familiar with the re-
cords and operating deviations found out in course of previ-
ous work shift.
• Inspect the Machine and its accessories before work is
started, check controllers, communication and safety equip-
ment, whether these are able to work as per the Manual. If
having found any defect that might endanger work safety
and unable to repair by yourself, do NOT start the Machine,
and report such defect to a person in charge.
• Fasten your seat belt when working with the Machine. Make
sure the seat belt and its mounting are not damaged!
• If finding any defect during operation, stop the Machine in-
stantly, lock safely against any undesired starting.
• Follow Machine run during its operation, and record any de-
fects found in the Operation Logbook.
• Keep Operating Logbook designed to make Machine ac-
ceptance and handover records between drivers, records
about defects and repairs during operation, evidence of ma-
jor events during a work shit.
• Before starting the engine the controllers must be in their
zero position, no persons may stay within hazardous reach
of the Machine.
• Use sound or light signal everytime the Machine is put into
operation, and this always before starting Machine engine.
• Before driving, make up air reservoir to 8 bar (116 PSI) pres-
sure in order to brake off the Machine.
• Before starting Machine operation, check the function of
brakes and steering.
• Following a warning signal the operator may start the Ma-
chine only when all the employees left a danger area. Con-
cerning (blind) workplaces unable to overlook properly, put
the Machine into operation only after the elapse of the time
required to leave danger area.
26
• Observe safety regulations during Machine operation, carry
out no activity that would jeopardise work safety, pay full
attention to Machine steering.
• Respect the technological procedure or the instructions by
a person accountable.
• When rolling in the workplace, adapt the rolling speed to
the terrain condition, work carried out and weather condi-
tions. Watch continuously the clearance so to avoid any col-
lision with a barrier.
• Upon completion or stop of the Machine operation during
which driver leaves the Machine, adopt measures against
any unauthorized use of the Machine and its spontaneous
start. Remove key from ignition box, turn ON the parking
brake switch, lock the cab, (dashboard cover in the Machine
with no cab), engine bonnet, use disconnector to cut off wir-
ing.
• With the Machine parked on a road or highway, take meas-
ures in line with regulations valid for roads and highways.
• Having finished the operation, park the Machine at a proper
place (flat, bearing area) so to avoid Machine stability en-
dangered, Machine interfering with traffic roads, Machine
exposed to falling objects (rock), and where exposed to no
other disaster of different kind (floods, landslides or others.).
• When working with the Machine is completed, record in
the Operation Logbook any Machine defects, damage or
repairs made. During immediate switching of drivers there
is the duty to notify directly the switching driver of the facts
found.
• Driver must use Personal Protective Equipment - work cloth-
ing, safety shoes, the clothing shall not be too loose, dam-
aged, hairs protected with proper head piece. During main-
tenance (lubricating, replacing operating media) make sure
hands are protected with appropriate gloves.
• With the Machine that has no cab, or when driving with 3rd
gear, use ear protection.
• Maintain the Machine fitted with the required equipment
accessories and outfit.
• Keep the Machine free of any oil dirt or flammable materials.
Keep driver’s control stand, climbing irons, walkway (step-
on) surfaces clean.
• In case Machine comes into contact with high voltage,
please adhere to the following principles:
- Try to move with the Machine away from the hazardous
area
- Do not leave driver’s control stand
- Give warning signal to others not to come near or touch
the Machine.
AP 240

2.1.4. Forbidden activities – safety and
guarantee
The following is forbidden:
• Filling the hydraulic circuit during the guarantee period in a
different way than using the hydraulic unit.
• Using the machine in case of an evident defect of the ma-
chine.
• Using the machine when any operating fluid level is low.
• Wilful repair of the engine – Except common changes of op-
erating fluids and filters, only the Cummins service depart-
ment can intervene in the engine, in particular in peripheral
components of the engine – alternator, starter, thermostat,
electrical installation of the engine.
• Using the emergency brake for turning off the engine dur-
ing normal operation of the machine.
• Operate the machine in potentially explosive atmospheres
(ATEX) and underground areas.
• To use the Machine following ingestion of alcoholic bever-
ages or narcotic substances.
• To use the Machine that would mean a threat to its technical
condition, safety (life, health) of persons, sites, facilities and
things, or eventually of road traffic and its continuity.
• To put into operation and use the Machine if other people
are staying within its hazardous reach - except for training a
driver by lector.
• Putting the machine into operation and using the machine
when a safety device (emergency brake, hydraulic locks,
etc.) has been removed or damaged.
• To travel and compact in such banks where Machine stabil-
ity would be impaired (overturn). The mentioned static sta-
bility of the Machine lowers by dynamic effects of travel.
• To travel and compact in such gradients of slopes where
hazard of ground torn off along with the Machine would oc-
cur, or loss of adhesion followed by uncontrolled skid.
• To control the Machine in some other way different from
that stated in the Operation Manual.
• To travel and compact according to the soil bearing capacity
at such distance from the edge of a slope, excavated trench-
es so to avoid any hazard of material fall (slide) or shoulder
torn off along with the Machine.
• To travel and compact at such distance from the walls, cuts,
slopes so to avoid any hazard of their sliding and covering
the Machine.
• To displace and transport people on the Machine.
• To operate the Machine within the hazardous range of
which there are other machines or transport vehicles except
for those that operate in mutual coordination with the Ma-
chine.
• To operate the Machine in places invisible from driver’s post
and where hazard to the persons or property might occur
unless work safety is secured another way, i.e. implicitly
through signalling by a person duly instructed – refer to the
Section named Hand Signals.
• To operate the Machine within protective zone of electric
line system and substations, and of gas.
• To drive over electric cables unless these are properly pro-
tected against any mechanical damage.
AP 240
OPERATION MANUAL
• To operate the Machine under reduced visibility and at
night unless Machine’s working area and the site have suf-
ficient lighting.
• To change driver’s position at the control stand from the left
to the right and vice versa while driving.
• Leave Machine driver’s position with the Machine running.
• To leave unsecured Machine - move away from the Machine
without preventing it from being misused.
• To disable safety system, protective system and locking sys-
tem or change their parameters.
• To use the Machine with oil, fuel, cooling liquid or other me-
dia leaking therefrom.
• To start the engine in some other way than stated in the Op-
eration Manual
• To locate other items (tools, instruments) at driver’s control
stand aside from items of personal needs.
• To lay away any material or other objects onto the Machine
• To remove any dirt or waste while the Machine is in opera-
tion
• To carry out maintenance, cleaning or repairs with the Ma-
chine not secured against its self-motion and accidental
starting, and unless contact between operator and moving
parts of the Machine is excluded.
• To touch moving parts of the Machine with human body or
objects and tools held in hands.
• To smoke and handle open fire when checking or filling in
fuels, changing or filling up oils, lubricating Machine, and
when inspecting battery and filing up battery
• To carry rags soaked with flammable materials on the Ma-
chine (inside engine compartment), and flammable liquids
stored in free vessels.
• Leave the engine running in enclosed, unventilated areas.
Exhaust fumes are dangerous to life.
• Drive with open doors.
• Perform any adjustments on the machine without the prior
consent of the manufacturer.
• Drive without the seat belt fastened.
• Shift electrical conductors.
• Use other than original spare parts.
• Interfere in the electrical and electronic units in any manner.
! CAUTION !
THE ADDITIONAL WEIGHT consists of 2 pcs and is
mounted as option from the bottom of the Machine
frame at Manufacturer. It is therefore considered to
be the integral part of the Machine. Any handling of
this weight is hazardous and is banned.
Please do not hesitate to contact your dealer, if
required!
Breaching these provisions can influence the judge-
ment of a possible complaint and effectiveness of
the engine guarantee period.
27
2.1. Main Safety Measures
2.1.5. Safety inscriptions and symbols used on the Machine

13 2 7
1
12
11 12
18
9 18

16

15 15
10 10
5
6 4 8

14

17

374040

28 AP 240
 OPERATION MANUAL

1. Risk of burn Do NOT open expansion tank lid until liquid cools down
below 50 °C (122 °F). (Symbol located on expansion tank)

2939
3409bz

2. Risk of Injury Maintain safe distance from rotation and heat part of the
Machine. (Symbol located on radiator)

3322bz

3. Cooling Liquid Cooling liquid is deleterious. Please, read the Operation

Manual when filling up or changing. (on radiator)

3323bz

4. Adjust at Standstill Do NOT carry make any adjustment or maintenance with

the engine running. Imminent risk of injury or being
caught by the rotating parts of Machine. (on dashboard)

2939

2584bz

5. No Washing Cover electric devices when washing the Machine. (on

dashboard)

2225bz

2939

6. Read the Manual Before you start the Machine, please, read thoroughly the
safety measures and the way to control the Machine and
its actuators, in the Manuals supplied with the Machine.
(on dashboard)

2702bz

AP 240 29
2.1. Main Safety Measures

7. Manual On the seat backrest stowage box.

2428bz

8. Disconnect Alternator Disconnect alternator before welding on the Machine!

(labelled on dashboard)

2668bz

9. Danger of explosion Imminent danger of explosion while handling the battery

- read Operation Manual. (Symbol located inside box of
the battery)
3017bz

10. Fasten the Belt Fasten safety belt before starting to move the Machine.
2939

(symbol located on control panel)

2687bz

24 t ROPS ROPS
(52910)
Lmin= 4m Lmin= 8m Lmin= 4m Lmin= 13ft

11. Lifting and Rigging Diagram L min

2x 12 000 kg
+
Lmin= 13ft Lmin= 26ft l = 1,95m

ROZPĚRA l = 1,95 m
+
l = 6,4ft
Use rigging of sufficient loading capacity. (symbol locat-
(2x 26455 lb)
THE BRACE l = 6,4 ft
DIE SPREIZE l = 1,95 m ed on LH side behind cab)
L min ŘETĚZY PRO UCHYCENÍ
NA PLOŠINĚ PŘEPRAVNÍHO
2x 12 000 kg PROSTŘEDKU
(2x 26455 lb) CHAINS FOR GRIPPING
ON CONVEYANCE PLATFORM

KETTEN FÜR DIE BEFESTIGING

AUF DER PLATTFORM DES
VERKEHRSMITTELS

2667bz

12. Lifting Lugs Lift the Machine in these lugs. (symbol located near lifting
lugs along both sides of the frame)

2153bz

3038

13. Noise Emitted L WA External noise of the Machine. (symbol located on frame’s

101dB
LH side)

3038bz

30 AP 240
 OPERATION MANUAL

14. Ear Protectors (Muffs) Use muffs with the Machine that has no cab. (on LH sde of
control panel)
2408bz

15. Rigging Points Tie the Machine in these points only. (symbols located
along both sides of frame)
3048bz

16. Risk of Injury Observe safe distance when operating the trimmer. (sym-
bol located on frame’s RH side)

2939

3352bz

3407

17. Machine braking Engage the gear before downhill driving! (symbol located
on the instrument panel)
3407bz

18. Distance from the machine Keep a safe distance from the machine. (Symbols located
at the back and on both sides of frames)

2939

2942bz

2775

19. Machine repair Do NOT start the engine! Hang the sign onto steering
wheel. The sign is supplied together with machine acces-
sories and should be kept in documentation locker.

2775bz

AP 240 31
2.1. Main Safety Measures
2.1.6. Hand signals

Signals given by an assistant operator if the operator cannot see

the travelling or working area or machine work devices.

SIGNALS USED FOR ALL THE COMMANDS

Stop
One arm stretched upward with open palm in the Operator di-
rection, second arm akimbo.
STOP

Sig. 1

Attention!
Both arms horizontally sideways raised - palms facing forward.

! Sig. 2

Attention, Danger!
Oscillating motion of both arms with antebrachium from the
position of arms horizontally sideways raised to the position or
arms sideways raised - bent and back.

! Sig. 3

SIGNALS FOR DRIVING

Drive away with the Machine

One arm stretched upward - bent with open palm, long motion
of antebrachium in the direction of the movement required,
second arm akimbo.

Sig. 4

32 AP 240
 OPERATION MANUAL
Slow driving forward - towards me
Both arms stretched upward, abreast, bent, with palms facing
the body - short oscillating motions of antebrachium, towards
the body, and back.

Sig. 5

Slow driving backward - away from me

Both arms stretched upward, abreast, bent, with palms away
from the body - short oscillating motions of antebrachium away
from the body, and back.

Sig. 6

Driving on the right

Left arm sideways raised, right arm akimbo.

Sig. 7

Driving on the left

Right arm sideways raised, left arm akimbo.

Sig. 8

AP 240 33
2.1. Main Safety Measures
Short motion
Both arms lifted forward, bent. Mark distance “X“ between
palms, then follows the motion signal.

X
Sig. 9

Engine start
Circular motion of antebrachium of right hand, with tight fist.

Sig. 10

Engine cut off

Oscillating motion of right hand sideways raised in front of the
body, to the sides.

Sig. 11

34 AP 240
2.2. Ecological and hygienic principles
When operating and storing the Machine
the User shall be liable to adhere to the
general principles of health and environ-
ment protection, as well as the laws, regu-
lations, and rules related to this issue, and
effective within the territory where the
Machine will be used.
2.2.1. Hygienic principles
• Oil products, cooling system media, battery media, and
coating compositions incl. thinners are deleterious materi-
als. Persons that come into contact with these products dur-
ing Machine operation and maintenance shall be liable to
follow general principles of own health protection and con-
form to the safety and hygienic directions from manufactur-
ers of these products.
Observe the following in particular:
- Eye and skin protection when handling the batteries
- Skin protection when handling oil products, coating
compositions and cooling liquids
- Wash your hands thoroughly upon work completion
and before meal, treat your hands with proper tissue
cream
- When handling the cooling systems, please observe in-
structions given in the Operation Manual supplied with
the Machine.
• Always store oil products, cooling system media, battery
media and coating compositions incl. organic thinners, and
the cleaning and preservation agents as well, in their origi-
nal properly marked packages. Admit no storage of these
materials in unidentified bottles or other vessels with regard
to the risk of being interchanged. Especially hazardous is the
potential of interchanging for eatables or drinks.
• If skin, mucosa or eyes are stained accidentally, or vapours
inhaled, promptly apply the first air principles. Get prompt
medical attention upon accidental ingestion of these prod-
ucts.
AP 240
OPERATION MANUAL
2.2.2. Ecological principles
• When discarded, the media for Machine’s individual systems
and some of the Machine’s parts will become waste of haz-
ardous properties against the environment.
This waste product category includes the following in par-
ticular:
- Organic and synthetic lubrication materials, oil and fu-
els,
- Cooling liquids,
- Battery media and the batteries themselves,
- Tyre media
- Cleaning and preservation agents,
- All filters and filter elements removed,
- All used and discarded hydraulic and fuel hoses, metal
rubbers or other Machine’s elements contaminated by
the abovementioned products.
• Manufacturer and Manufacturer-accredited contracting ser-
vice organizations or dealers take back these used materials
or parts without cost:
- oils
- batteries
- tyres
The mentioned materials and parts, when
discarded, shall be handled in line with
relevant national regulations to protect
individual components of environment,
and in conformity with the health protec-
tion regulations.
35
2.3. Machine preservation and storage
2.3.1. Short-term preservation and storage for
a period of 1 – 2 months
Wash and clean thoroughly the entire Machine. Before shutting
down the Machine for preservation and storage, please heat
the engine to its operating temperature while running. Park the
Machine on paved, flat surface, in safe location with no danger
of of damage to the Machine due to natural disasters (floods,
landslides, fire origination, etc.).
In addition:
• Repair spots where paint has been impaired,
• Lubricate all lubricating points, actuator cables (cable as-
semblies), joints of the actuators, etc.,
• Check water media have been drained,
• Confirm cooling liquid has the antifreezing properties re-
quired,
• Check condition of the battery charges; let them be re-
charged if required,
• Spread chromated surfaces of piston rods with preservation
fat,
• We recommend to protect your Machine against corrosion
through spraying the preservation agent (spray-applied),
and this especially in places of corrosion hazard.
The Machine treated like that needs no special preparation (set-
up) before its subsequent putting into operation.
! NOTE !
Fill the tank with fuel to the maximum level even in
the case of short-term shut-down of the machine
(for several days) as a protection against corrosion
on the tank walls.
36
2.3.2. Preservation and storage for the period
over 2 months long
To shut down the Machine the same principles apply like with
short time preservation.
In addition, we recommend the following:
• Remove the batteries, check their condition and store in
cold, dry room (recharge the batteries on regular basis),
• Bottom the drum frame up so the damping system has mini-
mal sag,
• Protect rubber elements with paint using special preserva-
tion agent,
• Inflate tyres to their required pressure, and protect against
sun radiation effects,
• Spread preservation fat over piston rods’ chromated sur-
faces,
• Preserve the Machine through spraying with special agent,
and this particularly in places of possible corrosion,
• Blind the induction manifold and exhaust of the engine with
double PE foil, attach thoroughly with adhesive tape,
• Protect headlamps, external back mirrors and other ele-
ments of external wiring through spraying with special
agent abd wrapping in PE foil,
• Preserve engine according to the Manufacturer’s Directions
- mark visibly the engine has been preserved.
! NOTE !
Following 6 months we recommend to inspect the
condition of preservation and renew it if required.
If storing the Machine under field conditions, please
check the parking place is not exposed to any flood-
ing hazard due to deluges, or whether any other
type of risk occurs within such area!
NEVER start the engine in course of storage!
Before restoration of the Machine service,
please dewax and wash the preservation
agents away with high pressure stream of
hot water added with normal degreasers
while observing Directions for Use along
with ecological principles.
Carry out dewaxing and washing of the
Machine at places equipped with collec-
tion sumps to catch rinsing water and de-
waxing agents.
AP 240
 OPERATION MANUAL
2.3.3. Dewaxing and inspection of a supplied
machine

Check the Machine according to the shipping documents.

Check no parts of the Machine have been damaged during
transportation, and that no parts are missing. Inform shipper
about any deficiencies.

Before restoration of the Machine service,

please dewax and wash the preservation
agents away with high pressure stream of
hot water added with normal degreasers
while observing Directions for Use along
with ecological principles.
Carry out dewaxing and washing of the
Machine at places equipped with collec-
tion sumps to catch rinsing water and de-
waxing agents.

AP 240 37
2.4. Machine disposal following its life cycle end
Upon Machine disposal following its life cycle end the User shall
be liable to follow the national regulations, waste acts and en-
vironmental policy acts. We therefore recommend to always
contact:
• Specialized companies with relevant authorization to deal
with these operations,
• Machine Manufacturer or Manufacturer-appointed accred-
ited contracting service organization.

Manufacturer bears no responsibility for

any damage caused to Users’ health or
for any damage to environment due to
non-adherence to the aforementioned
warning.

38 AP 240
2.5. Machine Description OPERATION MANUAL

22

17 18

3 2
12
15
14 5 16
13 11
4 7
6

1 8
10
21 19 24 21
19

9 20
20 25 23
374037

AP 240 Pneumatic Roller- Machine’s individual parts

1 - Roller Frame 15 - Additional Water Weight Closure*

2 - Engine 16 - Fuel Tank
3 - Engine Radiator + Hydraulic Circuit Cooler + Gearbox 17 - Driver’s Control Stand
Cooler 18 - Sprinkling Tank
4 - Gearbox incl. Torque Converter 19 - Tire Sprinkling
5 - Final Drive Housing incl. Differential 20 - Wheels
6 - Speed Reduction Transmissions 21 - Scrapers
7 - Propeller Shaft 22 - Protective ROPS Frame
8 - Parking and Emergency Brake 23 - Additional Weight
9 - Driving Brakes (rear wheels only) 24 - Ballast Space Lids
10 - Front Axle incl. Telescopic Cylinders 25 - Additional Water Weight Drain *
11 - Pump for Compressor Drive
12 - Power Assisted Steering * - If waterproof frame for additional weight incl. water me-
13 - Battery (cylinder’s LH side) dium is used with the Machine, then please refer to Speci-
14 - Hydraulic Tank (cylinder’s RH side) fication Manual - “The Weights”.

AP 240 39
2.6. Controllers & Control Instruments

47 2
3
ON
1
OFF OFF

44 42
43 41
5 6 7
20 8 20
A 9
13
11 11
15 2 20
16

B
10
12 22
14
21
15

20 3 4
19 1 17 20
18

24 25 26 27 28
23

29
30 31 32 33

34 35 36 37 38 39
374004B

40 AP 240
 OPERATION MANUAL
Driver’s Position
1 - Ignition Box
2 - Travel Controller
3 - Tire Inflation - optional *
4 - Tire Deflation - optional
5 - Gearbox Lubrication Pressure Gauge
6 - Gearbox Thermometer
7 - Power View Display
8 - Brake Circuit Pressure Gauge
9 - Tire Pressure Gauge - optional
10 - Emergency brake button
11 - Enabled Workplace Signalling
12 - Sprinkling Switch and Interval Control
13 - Engine ECM Diagnostics Socket
14 - Trimmer
15 - Direction-indicator lights
16 - Fuses
17 -Hand Lamp Socket
18 - Bonnet Lock to Unlock
19 - Acoustic Alarm for Brake Failure
20 - Ventilation Nozzles
21 - Accelerator Pedal - controls engine rpms - travel speed
22 - Brake Pedal - controls rear wheel brakes

A - Indicator Lamps
23 - Battery Recharging
24 - Parking brake
25 - Engine heating
26 - Hydraulic oil filter fouled
27 - Idle
28 - Direction - indicator lights
29 - Hydraulic oil level
30 - Brake failure
31 - Hydraulic oil overheated
32 - Air filter fouled
33 - Tire sprinkling

B - Switches
34 - Headlamps
35 - Rear lights
36 - Warning lights
37 - Hazard beacon
38 - Differential interlock
39 - Parking brake
41 - Window Washer Switch
42 - Front Wiper Switch
43 - Rear Wiper Switch
44 - Cab Lighting
47 - Air Conditioner - optional

* - With the standard version of the Machine the valve has been replaced with the end piece to connect hose incl. pressure gauge
for manual tire inflation (part of the equipment). For others, please refer to Maintenance Manual.

AP 240 41
2.6. Controllers & Control Instruments

5 6 7
8

11 9
11
2 2
13 0 I
II

III

IV F
1 1
F

2 N
2 N

3 3
10
R R

12

15 14
2A

N D

0
I
3397

START START
I
3236

3236

P 0

START
II
0

3 4 1

374005A

42 AP 240
 OPERATION MANUAL
Ignition box (1) Tire pressure gauge (9)
In ”0” position the Machine lighting will be connected along The minimum air pressure after air release from
with hand lamp socket. In ”I” position other consumers will be 2658 tyres has been adjusted to 1.5-2 bars.
connected. Spring-loaded position ”II” is used to start the en-
gine. Key can be removed in ”0” position only.
Note: Emergency brake button (10)
The key is identical to the key for locking the cabin door. Press to stop the Machine and its engine instant-
2582 ly in emergency event.

Travel controller (2)

It is used to adjust direction of running and for gear shifting via It is forbidden to use the emergency brake
a turning handle. for turning off the engine during normal
“F“ position - forward
operation of the machine.

“N“ position - idle (neutral)

“R“ position - backward
Horn pushbutton and fuse are part of the controller.
Position of “N“ fuse – controller interlocking.
0 Inflation valve (3), deflation valve (4)
I It is used to make up or deflate tyre air.
For pressure values, please refer to the
3397
Indication of workplace enabled (11)
• Indicates from which position (seat) the Roller travel is con-
trolled.
• If no indicator lamp (11) flashes with the ignition box key
turned ON then the engine can be started. If indicator lamps
(11) flash with the ignition key turned ON, then the engine
cannot be started since one or two travel controllers are not
in N position - idle indicator lamp does not light.

3397
Table in Section named Tyre Pressure
Control.

0
I
II
Sprinkling interval control (12)
Do NOT switch ON both valves simultane- Turn the switch left to start up the pump to run
III

IV

ously to ”I” position! 2659 continuously - tires will be sprinkled constantly.

Turn the switch to any of four positions in clock-
wise direction to turn ON sprinkling interval con-
trol.
Gearbox oil pressure gauge (5) Position I sprinkling for 10 s dwell for 10 s
Operating oil medium pressure must move with- Position II sprinkling for 10 s dwell for 15 s
sta06 in 17-20 bar range. Position III sprinkling for 10 s dwell for 22 s
Position IV sprinkling for 10 s dwell for 33 s
! CAUTION !
Sprinkling indicator lamp will light only when
When pressure drops below 17 bar, stop the pump is running.
Machine.

Socket (13) - to connect to ECM (Electronic

Control Module) designed to diagnose any
Gearbox oil temperature (6) defects or to adjust engine parameters.
3003
Operating temperature may move within 80 -
2185 120 °C range. Max temperature is 120 °C.

Trimmer (14) - downward, upward - optional

Power view display (7)

Multifunctional instrument to display engine function and fuel
reading. 2701

Brake circuit pressure gauge (8) Direction-indicator lights (15)

White indicator shows air pressure inside air res- 595200
2657 ervoir - adjusted to max 8 bar.
Red one indicates air pressure when braking - air
pressure from air brake valve to brake booster.

AP 240 43
2.6. Controllers & Control Instruments

16
0
I
II

III

IV

1 2 3 4 5 6 7 8

11 12 13 14 15 16 17 18

374011A

FUSES
Cut-out box (16)
It includes fuses of the following instruments:
1 (15A) - Mounting socket
2 (15A) - Rear lights
3 (15A) - Beacon, brake lights, cab lighting, horn
4 (15A) - Direction-indicator lights
5 (5A) - Front fender lights, rear lamps, instrument illumination
6 (15A) - Headlamps
7 (7.5A) - Gearbox solenoids, backing horn
8 (7.5A) - Differential lock solenoids, hydraulic oil level, engine start relay
11 (5A) - Indicator lamps (LEDs), measuring instruments, brake failure
12 (1A) - Diagnostics, Power View
13 (15A) - Wipers, washers
14 (10A) - Sprinkling
15 (25A) - Fans
16 (10A) - Trimmer
17 (-A) - Reserve
18 (-A) - Reserve

44 AP 240
 OPERATION MANUAL
9 (30A) - ECM electric motor supply
10 (-A) - Reserve for car radio 10
21 (80A) - Main fuse 9
22 (15A) - Air conditioner
21 22

374_klima

19 (125A) - Glowing
20 (125A) - Glowing

19

20
374013

Assembling lamp socket (17)

It serves to connection of the auxiliary assembling lamp 12 V on
the dashboard.

17

430022

Lock the bonnet (18) – by pressing the supports in marked-up

direction.

374019

AP 240 45
2.6. Controllers & Control Instruments

0
I
II

III

IV

24 25 26 27
23 28

29 30 31 32 33
374009A

Battery Recharging (23) - goes off when engine Direction-indicator lights (28) - LED lamp on
is started. workplace enabled will light.
2587 595200

Parking brake (24) - indicates Machine is Hydraulic oil level (29) - indicates lowered level.
braked.
2703 591507

Engine heating (25) - indicates necessity to ! CAUTION !

heat engine. When there is alarm the Roller stops and the engine
589502
goes off - starting is interlocked until oil is filled up.

Hydraulic oil filter fouled (26) - indicates filter

element to replace.
2276

Idle (27) - indicates position of both controllers

in ”N” idle (neutral).
596653

! CAUTION !
When starting, please check both controllers are in
idle position.

46 AP 240
 OPERATION MANUAL

0
I
II

III

IV

24 25 26 27
23 28

29 30 31 32 33
374009A

Brake failure (30) - indicates air pressure low-

ered in the circuit below 5.2 bar - simultaneously Air filter fouled (32) - indicates necessity to re-
with audio alarm. place filter element.
595148 594423
After starting up, the pilot lamp is turned on un- Note:
til the sufficient pressure in the brake circuit is
achieved. Compressor air intake leads to the filter.

If the pilot lamp turns on during driving, stop the

machine. Before driving the machine again, it is
necessary to repair the failure.
Tire sprinkling (33) - sprinkling pump turned
ON.
596128

Hydraulic oil overheated (31) - indicates max

temperature admissible (reduce power, cool
down).
2635

AP 240 47
2.6. Controllers & Control Instruments

0
I
II

III

IV

34 35 36 37 38 39

374010A

Headlamps (34) - incl. fender lights Parking brake (39)

596303 2703

While stopping the machine at any time,

Rear lights (35) the driver must apply the parking brake!

591668

Warning lights (36)

596191

Hazard beacon (37) - optional

592348

Differential interlock (38) - optional

596116A

48 AP 240
 OPERATION MANUAL
A Switches
B Heating А

374038

Window Washer Switch (41)

2260
A

Front Wiper Switch (42)

596625

Rear Wiper Switch (43)

596307 42 43 41
44
Cab Lighting (44) 374039

Fan Switch (45)

Temperature Control (46) B
45
0

III I MAX MIN

II

46

374036B

Air Conditioner (optional) (47)

Air-conditioning switch (A)
Air blowing intensity selector (B)
47

! CAUTION !
We recommend to start Air Conditioner 1x every 3 B A
weeks.
430101

AP 240 49
2.6. Controllers & Control Instruments
Cabin Induction Air Control (48)
Filter (49) B

Do not handle the controllers when

driving.

48
! CAUTION !
49
Close flap (48) to avoid any smell to penetrate into
the cabin. Do not keep the flap closed for too long –
fogging up of windows will occur.
374035B

Sucked air filter

430104

Filter for internal air circulation.

374015

Venting (50) - increases efficiency of cabin fans.

374N030

50 AP 240
 OPERATION MANUAL
Driver’s seat (51)
1 Backrest position
2 Longitudinal move
3 Seat suspension adjustment - as per driver weight indicator
4 Height adjustment - take the seat in your hand and slowly
lift it to adjust its height to higher position where it will be
1
arrested. When lifted to MAX position the seat will drop to its
2 MAX

lowest position. 2

1
0

Adjust seat before driving, and fasten

your seat belt! 3 4
374006

Document compartment (52)

A document compartment is located on the rear
2428 side of the seat back.

52

374007

Under both seats are locked box.

374028

Air reservoir valve control (53) - to release air (condensate)

from air reservoir

374N026

AP 240 51
2.6. Controllers & Control Instruments
Fire extinguisher (54) – optional equipment
Place for the installation of a fire extinguisher holder.

! CAUTION !
The manufacturer recommends that the machine be
equipped with a fire extinguisher.

374018

Window washer tank (55)

Refill with clean soft water - best is distilled water - incl. cleaning
and degreasing agent.

Before winter season, please fill the tank with de-icing, or

drain!

374N159

3351 Battery cut off switch (56)

30 sec
3351

0 30 sec
3351
I 0

Turn OFF the master switch after 30 sec

following the switch box key turned OFF
to maintain the data in the engine control
module - ECM.
374012А

52 AP 240
 OPERATION MANUAL
2.6.1. Power View control
3 2
1 Display
2 Red LED lights – ENGINE SHUTOFF – engine substantial
defect alarm
3 Yellow LED lights - WARNING – engine failure alarm, or 1
minimal fuel level in tank alarm
4 Menu selection pushbutton – to enter or exit menu
5 Pushbutton – to move cursor UP – illuminates data on dis-
play or moves parameter option to the left or up
6 Pushbutton – to move cursor DOWN – illuminates data on 4 7
display or moves parameter option to the right or down
7 ENTER pushbutton – selects menu or parameter, or con- 5 6 396011B
ceals/displays active error code

The red LED is lighting – reduce the en-

gine power, park the machine immediate-
ly at a safe place and turn off the engine!
Contact your dealer. Do not operate the
machine until the failure is removed!
The yellow LED is lighting – warning – en-
gine failure alarm, or minimal fuel level in
the tank alarm. Reduce the engine power,
park the machine immediately at a safe
place and turn off the engine! Remove
the failure or contact your dealer. Do not
operate the machine until the failure is
removed!
If a failure code is displayed, contact your
dealer.

AP 240 53
2.6. Controllers & Control Instruments
NAVIGATION BASIS

After the start-up, a four-parameter screen is displayed (engine

speed, coolant temperature, fuel level, number of engine oper-
ating hours). By pressing the left or right arrow, you display four 0 RPM 28°C
additional parameters. ENG RPM COOL TEMP

20% 100
FUEL LEVEL ENG HRS

431137

(engine oil pressure, engine load, el. system voltage, fuel con-
sumption rate)
Press the button MENU to display the main menu.
2.92 BAR 37 %
OIL PRES LOAD@RPM

28.6 VDC 3.1 L/HR

BAT VOLT FUEL RATE

431120

GO TO 1-UP DISPLAY – one-parameter display

Move the cursor (1) in the main menu onto the item and use the
button ENTER (2) to enter the submenu. GO TO 1 - UP DISPLAY
LANGUAGES
STORED CODES
ENGINE CONFIGURATION
SELECT UNITS
ADJUST BACKLIGHT
ADJUST CONTRAST

431121

Using the cursor (1) you can gradually display 9 pre-set param-
eters (engine speed, coolant temperature, engine oil pressure,
engine load in % at actual engine speed, el. system voltage,
number of engine operating hours, fuel consumption rate, fuel 0 1100 2200
level, acceleration pedal position).
Press the button MENU (2) to return to the main menu. 2000 RPM
Note: ENG RPM COOL TEMP
If the engine is at rest, the battery voltage is indicated. If the en-
gine is running, then roller’s el. system voltage is indicated.

2
1 396117

54 AP 240
 OPERATION MANUAL
LANGUAGES – menu to select a language
Move the cursor (1) in the main menu onto the item and use the
button ENTER (2) to enter the submenu.
GO TO 1 - UP DISPLAY
LANGUAGES
STORED CODES
ENGINE CONFIGURATION
SELECT UNITS
ADJUST BACKLIGHT
ADJUST CONTRAST

2 1 431122

Use the cursor and select a language, then confirm your selec-
tion using the button ENTER (1) and return to the main menu by
pressing the button MENU (2). ENGLISH *
FRANÇAIS
DEUTSCH
ITALIANO
ESPAÑOL

2 1
431124

STORED CODES – saved defects, which are not enabled.

Move the cursor (1) in the main menu onto the item and use the
button ENTER (2) to enter the submenu.
GO TO 1 - UP DISPLAY
LANGUAGES
STORED CODES
Note: ENGINE CONFIGURATION
The following message will appear on the display: “Requesting SELECT UNITS
fault codes“. Wait until it disappears. ADJUST BACKLIGHT
ADJUST CONTRAST

1 2
431125

If the word MORE appears, use the cursor to move to other

saved positions. By pressing the button ENTER, return to the
main menu. 1 of x

FUEL DELIVERY
PRESSURE VERY LOW
MORE HIDE

431126

AP 240 55
2.6. Controllers & Control Instruments
ENGINE CONFIGURATION – menu to browse engine param-
eters
Move the cursor (1) in the main menu onto the item and use the
GO TO 1 - UP DISPLAY
button ENTER (2) to enter the submenu. LANGUAGES
STORED CODES
ENGINE CONFIGURATION
SELECT UNITS
ADJUST BACKLIGHT
ADJUST CONTRAST

431138

Using the cursor you can move among the parameters.

ENGINE SPEED PT 1

850 RPM
< NEXT >

431136

SELECT UNITS – selection of units of measure

Move the cursor (1) in the main menu onto the item and use the
GO TO 1 - UP DISPLAY
button ENTER (2) to enter the submenu.
LANGUAGES
STORED CODES
ENGINE CONFIGURATION
SELECT UNITS
ADJUST BACKLIGHT
ADJUST CONTRAST

1 2
431128

Use the cursor to set (1) ENGLISH and the indicated variables
appear in PSI units (pressure), °F (temperature).
After you set METRIC KPA, the displayed variables are in kPA, °C
ENGLISH
units. METRIC Kpa
METRIC BAR
After you set METRIC BAR, the displayed variables are in bar, °C
units.
Using the button ENTER (2) confirm the variables and using the
button MENU (3) return to the main menu.

3 1 2 431129

56 AP 240
 OPERATION MANUAL
ADJUST BACKLIGHT – adjustment of the display backlight in-
tensity
GO TO 1-UP DISPLAY
Move the cursor (1) in the main menu onto the item and use the LANGUAGES
button ENTER (2) to enter the submenu.
STORED CODES
ENGINE CONFIGURATION
SELECT UNITS
ADJUST BACKLIGHT
ADJUST CONTRAST

1 2 431130

Set the backlight intensity using the cursor. By pressing the but-
ton MENU, return to the main menu.
ADJUST BACKLIGHT

396028

ADJUST CONTRAST – adjustment of the display contrast

Move the cursor (1) in the main menu onto the item and use the GO TO 1-UP DISPLAY
button ENTER (2) to enter the submenu. LANGUAGES
STORED CODES
ENGINE CONFIGURATION
SELECT UNITS
ADJUST BACKLIGHT
ADJUST CONTRAST

1 2 431131

Set the display contrast using the cursor. By pressing the button
MENU, return to the main menu.
ADJUST CONTRAST

396032

AP 240 57
2.6. Controllers & Control Instruments
SOFTWARE VERSION – informs about the software version
ADJUST CONTRAST
SOFTWARE VERSION
OEM

1 2 431132

OEM – service access

ADJUST CONTRAST
SOFTWARE VERSION
OEM

431133

58 AP 240
 OPERATION MANUAL
ENGINE FAULT SIGNALLING

ALARM SIGNALLING
The alarm signal indicated with the lighting yellow LED informs
about an engine malfunction – warning.

Engine failure alarm, or min fuel level in

tank alarm. Reduce the engine power,
park the machine immediately at a safe
place and turn off the engine! Remove
the failure or contact your dealer. Do not
operate the machine until the failure is
removed!
396034

A registered failure is indicated on the display through an error

code and a description of the failure.
When more errors are registered, please use the cursor to dis- 1 of x WARNING
play the registered failures step by step.

SPN110FMI10
HIGH COOLANT TEMP
MORE HIDE

396036

Press ENTER to confirm and hide the display.

1 of 1 WARNING

SPN110FMI10
HIGH COOLANT TEMP
MORE HIDE

396037

Return to the 1-parameter screen with the warning icon for the
active failure in the RH corner.

0 1100 2200

2000 RPM
ENG RPM COOL TEMP

396038

AP 240 59
2.6. Controllers & Control Instruments
Return to the 4-parameter screen with the warning icon for the
active failure in the RH corner.

0 RPM 28°C
ENG RPM COOL TEMP

20% 100
FUEL LEVEL ENG HRS
If a failure description and a code appear
on the display of the instrument board,
contact your dealer if it is impossible to
remove the failure.
431134

60 AP 240
 OPERATION MANUAL
ENGINE CUT OFF ALARM
The alarm signal indicated by the red lighting LED informs about
a serious failure of the engine – Turn off the engine.

Reduce the engine power, park the ma-

chine immediately at a safe place and turn
off the engine! Contact your dealer. Do
not operate the machine until the failure
is removed!

396040

A registered serious failure of the engine is indicated by an er-

ror code and a description of the failure on the display with the
warning message “SHUT DOWN“. Confirm and hide the display
using the button ENTER.
1 of x SHUTDOWN

SPN110FMI10
HIGH COOLANT TEMP
MORE HIDE

396042

1-parameter display with the warning icon “SHUT DOWN“ in the

upper right corner.

0 1100 2200

2000 RPM
ENG RPM
ENG RPM
COOL TEMP

396043

4-parameter display with the warning icon “SHUT DOWN“ in the

upper right corner.

Note 0 RPM 28°C

Press ENTER to display again the hidden error code for failure. ENG RPM COOL TEMP
Press ENTER once again to display either 1 parameter or 4 pa-
rameters. The warning icon is displayed until the failure is re-
moved. 20% 100
FUEL LEVEL ENG HRS

431135

AP 240 61
2.6. Controllers & Control Instruments

ERROR MESSAGES

Error message Signature

“WAIT TO START PREHEATING” is displayed The EMR is broadcasting a ‚Wait To Start‘message. Engine manufacturers
typically recommend against starting the engine while the EMR is
broadcasting this message. Once the EMR stops broadcasting this
message,this screen will no longer be displayed on the Power View.

“CANBUS FAILURE” is displayed The Power View has not received any valid J1939 CAN messages for at least 30
seconds.

“TIMEOUT EMR NOT RESPONDING” is The Power View sent a request to the EMR for Stored Fault Code (DM2)
displayed information, and the EMR did not respond to the request. This message on
the PowerView indicates the EMR may not support Stored Fault Code (DM2)
functionality over J1939.

“NO STORED CODES” is displayed The Power View sent a request to the EMR for Stored Fault Code (DM2)
information, and the EMR responded. There are zero stored codes.

“NO GAGE DATA” is displayed The Power View has no record of gages connected to the RS485 bus.

“NO DATA” is displayed in place of The Power View has not received data for the selected parameter for at least
a parameter value 5 seconds.

“NOT SUPPORTED” is displayed in place of The EMR is sending a message that it does not support this parameter.
a parameter value

“DATA ERROR” is displayed in place of The EMR is sending a message that there is a data error with this parameter.
a parameter value Or (PV101 only) FUEL LEVEL has been selected for display, ANALOG INPUT has
been set to FUEL LEVEL, but no Murphy Fuel Sender has been connected to
the analog input.

One of the 4-UP quadrants is empty No parameter has been selected for display in this quadrant.

Display is not readable, either very dim or The LCD contrast may have been over or under adjusted. Press and hold
very dark the MENU key for approximately 5 seconds. This will reset the LCD contrast
setting to factory default.

62 AP 240
2.7. Machine Control and Usage OPERATION MANUAL

2 2
0
I
II

III

F IV F
1 1
N
2 N
2
3 R 3 R

10

0
I
3397

START START
3236

3236

P 0
I
START

II
0

374020A

3351

3351

30 sec

30 sec
0

374014

AP 240 63
2.7. Machine Control and Usage
2.7.1. Engine starting

Before first starting the engine, check

daily the amount of oil in the engine and
hydraulic tank, fuel level in fuel tank, oil
level in gearbox, brake fluid level, cool-
ing liquid level. Make sure no parts on the
Machine are loose, worn-out or missing.

Before starting the engine, give horn

alarm and make sure nobody is endan-
gered due to engine start!

How to start the engine

• Switch ON battery disconnector.
• Check that both travel controls (2) are in the neutral posi-
tion, the parking brake is active and the emergency brake
button (10) is off. Turn key (1) to position ”I“. Indicator lamps
(LEDS) for recharging, idle, parking brake or glowing (de-
pending on ambient temperature) will light up. Power View
(7) (refer to section called “Power View Control”) will get en-
abled. When glowing LED goes off, please start by turning
ignition key to II position.

! CAUTION !
Starting will be interlocked if:
If the emergency brake button is on.
Roller is not braked via parking brake.
Both travel controllers are not in idle position.
Hydraulic oil level LED is ON.

Do NOT use accelerator pedal to start the

engine, start with engine idling!
Do NOT start for over 30 sec. Repeat start-
ing only after 2 minutes.
Repeat starting max 3x, following that
carry out troubleshooting within fuel sys-
tem. Smoke absence in exhaust pipe indi-
cates failed fuel supply.
When started, the recharge LED must go
off within 15 sec.
Do NOT increase rpm sharply, let the en-
gine run unloaded, at idle thrust for 3÷5
minutes depending on ambient tempera-
ture for the period of filling the brake sys-
tem up to 7 bar pressure. Do NOT leave
engine run idle for over 10 minutes, oth-
erwise engine may get damaged!
It is forbidden to tow-start the engine!

64 AP 240
 OPERATION MANUAL
When starting with power supply (12 V), please adhere to
the procedure designed for connecting the battery jump
cables:
1. Connect cable to + pole of discharged battery.
2. Connect second cable end to +pole of charged battery.
3. Connect cable to - pole of charged battery.
4. Connect second cable end to such part of started Ma-
chine that is hard-wired with engine 12 +
0
Disconnect cables in reverse order. v
–

+
12
0
v

374116

AP 240 65
2.7. Machine Control and Usage
2.7.2. Travel & Reversation
11
Check that both travel controls (2) are in
the neutral position, the parking brake is
active and the emergency brake button
(10) is off.
1

Before starting to move the Machine use

2
3

horn to give a warning and wait long

enough for any persons present to leave
the hazardous area within the Machine vi- 22
cinity in time (area beneath the Machine)!
21
Make sure the area in front of and be-
hind the Machine is free and that no per-
sons are within the working reach of the
Machine!
N

Machine driving off and stopping

• Position the lock (2A) of the travel controller to the position
“D”. 374022A
• At the engine idle speed, engage gear 1, 2 or 3 by turning
the gear selector (2). Engage gear 3 only for transporting the
machine.
• Using the switch (39), release the machine brakes – the park-
ing brake pilot lamp turns off (24).
• Using the travel controller (2), select the forward direction of
travel “F” or the rearward direction of travel “R” – the active
driver’s place pilot lamp turns on (11) and the neutral pilot
lamp turns off (27).
• Increase the engine speed using the accelerator pedal (21)
and the machine drives off in the selected direction.
• Slow down the machine by decreasing the engine speed us-
ing the pedal (21) or by braking the service brake pedal (22).
• To stop the machine, use the service brake pedal (22).

Change of driving direction (reversing):

• When reversing, let the machine stop or use the service
brake (22) gently. After stopping the machine, engage the
appropriate gear using the travel controller (2) and drive off
again.

It is forbidden to reverse (i.e. using the

travel controller (2), to activate the re-
versing) when the machine is moving and
when the accelerator pedal (21) is pressed
down.

66 AP 240
 OPERATION MANUAL
Shifting gears:
• Gear shifting from 1 to 2 or from 2 to 3 during driving can
be done by turning the gear selector (2) under load. Gear
shifting from 3 to 2 or from 2 to 1 is only permitted at the
machine speed corresponding to the gear engaged.
• When driving uphill, engage a lower gear in time.

If there is a loss of traction, a decrease of

tractive force or a significant decrease of
the engine speed, engage the lower gear
using the travel control (2)! If the machine
is equipped with an ATC differential lock
function, enable this function using the
switch (38).

Differential lock use:

• Use differential interlock only when recovering the Machine!
Switch OFF the interlock once heavy conditions are over-
come - danger of damage to differential or tires.

It is forbidden to activate the differential

lock when the machine is moving!
It is forbidden to use the differential lock
under good adhesion conditions and
when turning!

Note:
When engaging one travel control (2) from ”N” to ”F” or ”R” the
ENABLED workplace - signal lamp will light up.
All commands to change direction of driving and change speed
gears on the non-active place of the driver (on the other side)
are disabled!
ENABLED workplace - signal lamp will go OFF with the engine
shut off.

NEVER drive downhill with travel control- 1 2 3

ler in “N“ position (idle). The gear engaged
during downhill driving must correspond N N N
to the gear engaged should there be up-
hill driving. (the higher the slope gradient
the lower the gear).

1
2
3

374115

AP 240 67
2.7. Machine Control and Usage

NEVER drive a Roller over 18 tons of its M < 18 t [39690 lb] M > 18 t [39690 lb]
weight on a slope with gradient over
25 %.
NEVER drive a Roller over 18 tons of its
weight with 2nd and 3rd gear engaged on
a slope that has gradient over 15 %.

MA
For the maximum permissible slope gra- 30%X MAX
dient when driving uphill and across the 25%
slope gradient, see figures.
The values given are lower depending on
adhesive conditions and the machine in- 374114
stantaneous weight!

M – machine weight

MAX
10%

374113

NEVER change steering place - shifting

from LH seat to RH one and vice versa
while driving. Stop the Roller, brake it a
then change the seat!

Unless the engine cooling liquid temper-

ature reaches min 60 °C, do not load the
engine at full capacity!
When oil temperature in gearbox rises
over 120 °C, stop the work, stop driving
and cool gearbox oil down to optimal 80-
100 °C in situ at increased engine speed
of 1500 rpm. If oil heats up to 120 °C fre-
quently, change the driving manner - shift
gears more frequently, clean oil cooler!
Never use parking brake for normal brake
application.

! CAUTION !
When you select direction of running via controller,
and after braking off the Machine will start to move
slowly even with the engine idling.
While driving, keep the engine at rather high rpm
to achieve better controllability of steering the
Machine.

68 AP 240
 OPERATION MANUAL
2.7.3. Emergency stop of the Machine
0 I
II

Use in the event of engine unable to shut III

off via its key, Machine unable to stop via IV

shifting the controller to idle, or with the

use of brake pedal, or with parking brake
unable to apply.

• After pressing the emergency brake button – the machine

stops (brakes) and the engine stops.

374024A

• Before starting the engine again, move the control (2) to

the neutral position, release the emergency brake button
according to the arrow, turn on the parking brake. Turn the
key to the “0” position and start. 2
0
I
II

III

1 IV

2
3

0
1
I
3397

0
START START
3236

3236
I
P 0

START
II

374025

AP 240 69
2.7. Machine Control and Usage
2.7.4. How to stop the Machine and the engine

• Before braking to a stop, shift the controller (2) to neutral,

and when stopped, switch ON the parking brake, shut OFF 2
the engine and pull out the key (1).
0
I
II

III

1 IV

2
3

Note:
With the key pulled out from ignition box the Roller will auto-
matically be braked.

With the engine running the parking 0

1
brake switch must be ON with the Roller I

at standstill!
3397

0
Do NOT shut off the engine immediately, START
3236

3236
START
I
instead let it run for 3 ÷ 5 minutes at idle
P 0

START
II

thrust at 850 rpm for turbocharger to cool

down. 374025A
When work is completed, always discon-
nect the battery via battery disconnector!
Observe time limit of 30 sec. before dis-
connecting the battery following ignition
box switched OFF so to maintain Machine
operation data in ECM of the engine.
NEVER park your Roller on a slope with
gradient of over 15 %!

70 AP 240
 OPERATION MANUAL
2.7.5. Machine parking

• Shut down the machine on a flat and solid surface where

there is no potential natural hazard (landslides, possible
flooding, etc.)
• After Roller stops, turn ON parking brake, shut off engine.
0
I
II

III

1 IV

• Secure the machine with wheel chocks or other suitable

3

means preventing unintended movement.

0
I
3397

0
START START
3236

3236
I
P 0

START
II

374025B

• Switch off battery disconnector.

3351

0 30 sec

I 0

374012А
• Clean the Machine of any rough dirt (scrapers & tires).
• Make overall inspection of the Machine and repair any de-
fects that have occurred during operation.
• Check pressure in tires and inflate up to 8 bar pressure.
• Lock the cab (or eventually dashboard cover with the Ma-
chine that has no cab).

NEVER dead-park the Roller on a slope

with gradient of over 15 %!. Dead park the
Machine on pavement area in place with
no potential of natural hazard (landslide,
potential flooding, etc.).

! CAUTION !
Fill up fuel in the filter following a rather long shut-
down of the Roller.
374029

AP 240 71
2.7. Machine Control and Usage
2.7.6. Watering and scrapers

• When compacting fresh-laid asphalt coat, please turn ON

the sprinkling and set adequate sprinkling interval. Use ap-
propriate separation emulsion.

0
I
II

Lift the scrapers during normal compac- III

tion work on soil and when driving. IV

374026A

• Lower the front scrapers (1) and rear scrapers (2).

2
1
374027C

2.7.7. Additional weighting of the machine

• It is used to increase the weight of the machine and com-

paction efficiency.
• Mount the weight evenly in the whole frame. You can also
increase the machine weight only in the front or only in the
rear part of the frame.

435116

Weight type Weight kg (lb)

Empty ballast tank 1100 (2430)
Weight 6 t (concrete, steel) 6000 (13230)
Ballast tanks filled with concrete 2800 (6170)
Water 3000 (6610)
Sand 4500 (9920)
Scrap up to the maximum machine weight 24000 (52910)

72 AP 240
 OPERATION MANUAL
2.7.8. Edge Cutter

• Press the switch to lower the edge cutter to its end position
and vice versa.

374111

• When operating the edge cutter, switch ON the sprinkler

and open the valve near edge cutter disc.

Confirm nobody is in hazard before lower-

ing, lifting.
374109A

Scraper plate location.

374109B

Scraper plate
1 - Name – always mentioned only in the English version
2
2 - Type
3 - Serial number
3459
3
4 - Maximum weight TYPE

5 - Year of manufacture AMMANN CZECH REPUBLIC a.s.

Náchodská 145
SERIAL NUMBER 4
549 01 NOVÉ MÌSTO NAD METUJÍ
CZECH REPUBLIC
MAXIMUM MASS
DESIGNATION

YEAR OF CONSTRUCTION

MADE IN CZECH REPUBLIC

1 5

3459

AP 240 73
2.8. How to transport the Machine
• The machine can move on its own between working sites.

When moving, observe the safety meas-

ures applicable to the working site.

• When on the road, the machine should be transported on

a vehicle.

When transporting the machine on a vehi-

cle, observe the regulations in force in the
given territory.

When loading and unloading, the vehicle

transporting the machine must be braked
and mechanically protected against acci-
dental movement using scotch blocks (3).
If the Machine has been equipped with
differential interlock - then lock in the in-
terlock before running onto the carrier’s 2 2
platform!
The machine on the vehicle must be
properly tied and mechanically secured
against longitudinal and lateral displace- 3 3 1
ment as well as against tipping (1). The
drums must be secured using scotch
blocks (2). 374117

The manufacturer recommends that the

machine should be tied starting from the
left rear lashing point. After the machine
has been tied, the means of lashing must
not be in contact with tyres as such con-
tact could result in damage to the tyre.

74 AP 240
 OPERATION MANUAL
2.8.1. Loading the machine

• Use a loading ramp or crane to load the machine onto the

transport vehicle.

2.8.1.1. Loading the machine using a ramp

• When loading the machine using a ramp, all safety regula-

tions related to loading of the machine valid in the place of
loading must be adhered to. The ramp must have appropri-
ate loading capacity, antislip surface and must be stored on
a flat surface. We recommend that you adhere to regulation
MAX 30 %
BGR 233.
• Maximum permissible incline of the ramp is 30 %. 430005

Non-adherence to the prescribed param-

eters of the ramp may result in damage to
the machine.
When loading the machine, a second per-
son must be present to signal approach
onto the ramp. See the list of hand signals
in chapter 2.1.6.

Pay increased attention when loading the

machine. Improper handling can cause
serious injury or death.

2.8.1.2. Loading the machine using a crane 24 t

ROPS ROPS
(52,910 lb)
L min
2x 12 000 kg
Lmin = 4 m Lmin = 8 m Lmin = 4 m
• When loading with crane the Roller is fitted with lifting lugs. (2x 26,455 lb) A = 1,95 m
Lmin = 13 ft Lmin = 26 ft Lmin = 13 ft
A = 6.4 ft
L min
2x 12 000 kg
Observe the relevant national safety (2x 26,455 lb) A
measures when loading the machine with
a crane.
Beware of Roller’s actual mass incl. weight and ad-
ditional load in ballast spaces of Roller!
Use only the designed lifting lugs intended to tie the
ropes.
Binding may only be performed by a binder with a
374176
binding certificate.
Use lifting equipment and rigging of sufficient load-
ing capacity.

! CAUTION !
When using ropes shorter than 8 m (26.3 ft), insert
cross bar (A) 1.95 m (6.4 ft) long between the ropes
overhead the cab.

Do NOT enter under the hung load!

AP 240 75
2.9. Machine work under heavy conditions
2.9.1. Machine towing

To tow the Roller, use towing hitch mount-

ed in the Machine front. Towing hitch is
optional.
When the roller has no coupling, towing
the roller is banned. Move the roller us-
ing a crane. The loading capacity of the
crane and slings must be higher than the
machine instantaneous operating weight!

• Unless the brake circuit has pressure over 5.2 bars and unless
the engine is working to make up the pressure, you must
use a fixture (optional) to brake off the Roller for towing.

374110

• Dismantle floor covers between the seats.

374N058A

• Dismantle the bolting.

374042

76 AP 240
 OPERATION MANUAL
• Screw on the fixture (1), (2) into the spring cylinder (3) in
order to release the shoes that grip the parking brake disc. 1

Before braking off, use Scotch blocks for

wheels to secure the Roller against any
spontaneous moving! 2
All the brakes are disabled! 3
No persons may dwell on the towed Roller
with its engine not working.
374N161T

With the engine of the towed Roller not

working, the steering will not work, the
operating brake is not fully operable (un-
able to generate air pressure). Fixture has
been used to brake off the parking brake
and consequently the Roller is not be-
ing braked. Therefore when towing the
Roller, downhill in particular, NEVER use
the hauling cable, use the tow-bar!
When towing, use intact hauling cables or
tow-bar of loading capacity equal to 1.5
multiple of instantaneous weight of the
Roller towed. NEVER use a chain!
When towing, make sure persons present
stay within sufficient distance to avoid
their injury if the hauling cable breaks or
the hitch is damaged.
One must maintain the minimal angular
displacement of straight angle of hauling.
Maximal misalignment possible is at an
angle of up to 30°.
One must maintain the continuous mo-
tion when towing. Do NOT exceed the
towing speed of 2 km/hr. (1.2 mph).
Tow the Roller for a distance as short as
possible – to recover it when bogged
down, or to remove it as an obstruction
during its defect. Do NOT tow for a dis-
tance over 300 m (0.19 mil) long.
The size of the towing machine should
correspond with the broken Machine.
Make sure it has sufficient pulling power,
weight and brake effect.
Unless the engine works, secure the Roller
immediately after towing against any mo-
tion, and then remove the fixture away
from the parking brake.

! CAUTION !
These are general requirements for safe hauling
of damaged Machine under normal conditions.
Consult with your dealer any and all different situa-
tion that may occur when towing.

AP 240 77
2.9. Machine work under heavy conditions
2.9.2. Machine operation during its running-in
period
Upon the commencement of the operation of a new ma-
chine and during the first 30 hours of operation, do not load
the machine at its full capacity.
2.9.3. Machine operation at low temperatures
The compaction in the winter period depends on the content of
fine particles and water in the compacted soil. The soil becomes
more solid and more difficult to compact with a decreasing tem-
perature below the freezing point.
Dry soils and stony soils can be compacted and non-frozen ma-
terials (before the soil freezes up) can be quickly compacted at
temperatures below 0 °C (32 °F).
Preparation for works at low temperatures
• Check the concentration of the engine cooling liquid.
• Exchange the engine oil with the recommended one for the
respective low ambient temperatures.
• Use the hydraulic oil of the corresponding kinematic viscos-
ity.
• Use the winter fuel.
• Check the battery charge.
Note
Heating the batteries to approximately 20 °C (68 °F) (by remov-
ing and storing the batteries in a warm room) will reduce the
limiting starting temperature by 4 to 5 °C (39.2 to 41 °F).
The minimum temperature of the engine cooling liquid is 60 °C
(140 °F). The maximum temperature is 100 °C (212 °F).
! CAUTION !
When using the HV 100 oil in the hydraulic system,
the machine must not be started at ambient temper-
atures below +2 °C (36 °F).
78
2.9.4. Machine work under high temperatures
and humidity
Engine power lowers with growing air temperature and humid-
ity.
• Every 10 °C of temperature increase means power drop by
up to 4 % (at constant humidity),
• Every 10 % of increased relative humidity means power
drop by up to 2 % (at constant temperature).
Note
• In the environment where hydraulic oil temperature moves
constantly round 90 °C (194 °F), we recommend to have hy-
draulic oil replaced by the oil with HV 100 kinematic viscos-
ity.
• For planetary gearbox with hydraulic torque converter with-
in the environment characterized as TROPICAL, we recom-
mend to use oil of SAE 30 viscosity value that corresponds to
the performance classification of Caterpillar TO-4.
2.9.5. Machine work in high altitudes
• With altitude growing the atmospheric pressure and specif-
ic gravity of intake air decrease, and in connection therewith
the engine performance lowers.
• If engine smokes black in the altitudes of over 1500 m,
please contact service department of engine manufacturer
(Engine Operation and Maintenance Manual) and this man-
ufacturer will adjust the injection pump accordingly to suit
such conditions.
The engine power is affected by the envi-
ronment in which the machine is working.
The machine may be used up to a maxi-
mum altitude of 3,658 m (12,000 ft).
2.9.6. Work of the machine in the dusty
environment
• When working in a very dusty environment, please cut short
the intervals for replacement of suction filter elements, cut
short the interval for cleaning the coolers, for replacement
of cabin’s dust filter, refer to Machine Maintenance Table.
AP 240
 Notes

AP 240 79
 Notes

80 AP 240
 MAINTENANCE MANUAL

3. MAINTENANCE MANUAL

AP 240
(Cummins Tier 3)

AP 240 81
82 AP 240
3.1. Safety standards and other maintenance regulations
3.1.1. Safety of machine maintenance
Carry out lubrication, maintenance and adjustments:
• By professionally trained personnel
• In line with safety instructions given in the Operation Man-
ual
• According to schedule given in the Lubrication Chart follow-
ing the hours actually worked
• On the machine located on flat solid surface, secured against
self-motion (scotch blocks), and this always with the engine
OFF, key removed from ignition box, and the wiring cut off
• Only after Machine Repair sign is attached onto steering
wheel (the sign is supplied together with machine acces-
sories)
• On machine parts cooled out
• After having cleaned the machine, lubrication points and
maintenance locations
• Using proper, undamaged tools
• Through replacement with new original parts as per the
Spare Parts Catalogue
• With sufficient lighting of the entire machine in the event of
lowered visibility and at night
• so the guards and safety elements are reinstalled again
upon work completion
• through retightening bolted connections – with torque
specified, and through checking the connection tightness
• with the operation media heated – beware of burns – use
recommended media, only.
Upon completion of the adjustment or
maintenance, please examine the func-
tion of all safeguard equipment!
AP 240
3.1.2. Fire precautions during operation media
exchanges
• In terms of fire hazard the flammable liquids used on the
Machine have been divided into three hazard classes:
IInd Hazard class – Diesel oil
IVth Hazard class – mineral oils, lube greases
• Oil exchange point shall be located so it does not interfere
with the explosion or fire hazard area.
• It shall be identified with notice boards and signs of no
smoking and no use of open flame.
• Handling area shall be sized so the capture the amount to
flammable liquid equal to the capacity of biggest vessel,
transport container.
• It must be equipped with portable fire extinguishers.
• To handle the oil, Diesel oil, please use such vessels like met-
al barrels, canisters or sheet-metal cans.
• Transport containers shall be properly closed when stored.
• Vessels shall have one opening, be stored with the opening
on top, and secured against any flowing out or dripping of
their content.
• Vessels shall be designated with indelible inscription indi-
cating the content and flammability class.
83
3.1. Safety standards and other maintenance regulations
3.1.3. Ecological and hygienic standards Ecological standards

When operating and maintening the machine the owner is

obliged to keep the common regulations of health and environ- The fills of individual machine systems
ment protection and the laws, regulations and promuglations, and also some parts are after black-
correlative to this problems and valid in the region of the ma- out (dismounting, changing the fills)
chine use. the garbage with risk attributes for the
environment.

Hygienic standards

• The petroleum products, cooling systems fills, accumula- • To this category of waste products includes:
tors, brake liquids and fills and paints including the thinners - organic and synthetic lubricants, oils and fuels
are harmful materials. Workers that come into contact with
these materials during the service and maintenance of the - brake fluids
machine, are obliged to keep the common standards of - cooling liquids
health protection and they must keep the safety and hy-
- accumulator filling and accumulators themselves
gienic manuals of the manufacturers of these materials.
- the conditioner systems fillings
• We want you to focus your attention mainly on these areas:
- cleaning and preservative materials
- eyes and skin protection when manipulating with the
accumulators - all dismounted filters and filter inserts
- skin protection when manipulating with the petroleum - all used and blackouted hydraulic and fuel pipes, rubber
products, paints, cooling liquids and brake liquids steels and other machine parts, contaminated by mate-
rials above
- proper washing the hands after finishing the work and
before the meal, treat the hands using the appropriate
regenerating cream
- when manipulating with cooling systems, keep the ma- With materials and parts listed we must
chine manipulating manual instructions. work after blackout according to the ap-
propriate national regulations for in-
dividual environment parts protection
• The petroleum products, cooling systems fills, accumulators and according to the health protection
fills, brake liquids and paints including the organic thinners regulations.
and also cleaning and preservative means always store on
a original, properly signed covers. Don’t allow storing of
these materials in the non-marked vessels and other cans
due to danger of exchange. Extremely danger may be the
exchange with meal or drinks.
• In the case of accidental stain of the skin, mucous mem-
branes, eyes or of inhalation of the vapour, apply immedi-
ately the first aid. In such case find the emergency first aid.
• When working with the machine unequipped with the cab,
or with opened windows and cab door, always use the ears
protections of convenient kind and design.

84 AP 240
3.2. Media Specification MAINTENANCE MANUAL

3.2.1. Engine Oil

2412

Engine oil has been specified according to the performance

classification and viscosity classification.
°F °C
122 50

Performance classification as per

API (AMERICAN PETROLEUM INSTITUTE)
104 40
CCMC (COMMITTEE OF COMMON MARKET AUTOMOBILE CON-
STRUCTORS)
ACEA (ASSOTIATION DES CONSTRUCTEUERS EUROPPÉENS DE
AUTOMOBILE) 86 30

Viscosity classification
Ambient temperature and type of operation at the location 68 20
where the Machine is used are decisive to determine the SAE

15W - 40
(Society of Automotive Engineers) viscosity class.

Use of admissible oils under API: CH-4/SJ; CI-4 50 10

CCMC DHD1
ACEA: E-5
32 0

10W - 30
Year round SAE 15W-40, refer to the Table.

Note:

5W - 30
Exceeding low temperature limit will not lead to any engine 14 -10
damage. It may only cause problems when starting the engine.
It is appropriate to use universal multi/grade oils so there shall
be no need to exchange oil due to ambient temperature change.
-4 -20
The use of synthetic engine oils is possible if performance and
viscosity classification of oils corresponds to mineral oils recom-
mended.
Exchange periods must be observed to be of identical intervals
-22 -30
like when using mineral oils.
To make starting easier at the temperatures below 0 °C (32 °F)
the engine oil producer recommends SAE 10W-30 oil.
-40 -40
282N224T
Exceeding upper temperature limit must
not last too long due to lowered lubricat-
ing capability of oil.
When using oil under API CF-4/SH you
must halve exchange interval, i.e. 125
hours or 6 weeks.

AP 240 85
3.2. Media Specification
3.2.2. Fuel
The following Diesel oils are used as engine fuel:
EN 590
ASTM D 975-88: 1-D a 2-D
Therefore use winter Diesel fuel at out-
door temperatures below 0 °C (32 °F).
Special Diesel fuel with additives in-
tended for very low temperatures must
be used at outdoor temperatures below
-15 °C (5 °F) (”super Diesel”).
86
Use of biofuel (Diesel fuel)
Using the fuel mixture under the trade name of Bionafta is in
principle approved by the engine manufacturer for the engine
on the machine if it conforms to the specifications under EN
14214 or ASTM D6751.
Before using Bionafta on the machine, make sure that it is sup-
plied by a reputable supplier who supplies fuels corresponding
to the above-mentioned standards.
Always ask the supplier of Bionafta for information concerning
the condition under which it can be used.
Guarantee for the engine will be rejected
when using Bionafta not conforming to
the above-mentioned standards and if
the fuel system or engine is damaged as a
result of using improper Bionafta!
! CAUTION !
When using Bionafta, power can be reduced by up
to 12% depending on the used mixture of Bionafta.
Therefore, do not adjust the engine or the setting of
the injection pump for increasing the power in any
case. Never mix the fuel mixture at the place of use.
Bionafta has a higher cloud point at a low ambient
temperature, which leads to the creation of wax crys-
tals in the fuel resulting in the fuel filter clogging.
When using Bionafta, it is necessary to shorten the
intervals of the engine oil exchange and replace-
ment of an oil filter and fuel filter.
When changing over to Bionafta, the action of
Bionafta releases corrosion and impurities cre-
ated on the fuel tank internal walls. Impurities are
brought by the fuel to the filter catching them and
the filter must be replaced afterwards.
Bionafta has a higher ability to absorb atmospheric
moisture, which results in the condensation of at-
mospheric moisture on the internal walls of the tank
and a higher content of water in the fuel and the
need for more frequent discharging of water from
the fuel filter separators. The possibility of the oc-
currence of the problem increases in cold weather.
If Bionafta (Biodiesel) is used all the year round, it
is necessary to clean the fuel system under the en-
gine operation with a clean diesel fuel for at least 30
minutes before parking the machine for longer than
3 months. Further, it is necessary to drain off the
fuel tank, clean it, and either fill it with diesel fuel
or minimise the occurrence of moisture and limit the
microbiological growth inside the tank. Consult the
measures with the fuel supplier.
AP 240

3.2.3. Coolant
2152
The coolant specification must meet requirements of:
CES 14603
To fill the cooling circuit, use the coo-
lant in the mixing ratio of 50%/50% with
high-quality water (thermal protection up
to -37 °C).
The maximum admissible concentration
of the coolant is 60% (thermal protection
up to -54 °C).
Change the coolant every 2,000 hours of
operation, after 2 years at the latest.
Note:
The machines are filled with a cooling solution with the Bant-
leon Avia Antifreeze NG coolant, specification CES 14603, ASTM
D 4985, ASTM D 6210 at the manufacturer’s during the produc-
tion.
It is a coolant based on monoethyleneglycol containing silicates.
It does not contain phosphates, nitrates, amines and borates.
There is an Avia NG label placed at the point to fill the coolant
into the machine.
Refill the cooling circuit with the same or
a completely miscible coolant of the re-
quired specification.
If the use of a different, immiscible cool-
ant is necessary, the cooling circuit must
be completely drained and cleaned with
clean water repeatedly, at least 3 times.
However, it is not allowed to use a coolant
of a different specification than stated by
the engine manufacturer.
The coolant protects the cooling system
from freezing, corrosion, cavitation, over-
heating, etc.
It is forbidden to operate the machine
without coolant even for a short time.
It is forbidden to use a coolant of a dif-
ferent than prescribed specification and
base. The engine and the cooling system
can get damaged and the warranty lost.
Always check the ratio of antifreeze cool-
ing agent in the coolant with a refractom-
eter before the winter season starts.
AP 240
MAINTENANCE MANUAL
Water quality
Do not use hard water with a higher content of calcium and
magnesium, which brings calculus formation, and with a high-
er content of chlorides and sulphates, which causes corrosion;
refer to CUMMINS Engine Operation and Maintenance Manual.
The maximum content of compounds of calcium and magne-
sium is 170 milligrams – hardness of water.
The maximum content of compounds of chlorine is 40 milli-
grams.
The maximum content of compounds of sulphur is 100 milli-
grams.
Safety instructions:
1) Protect your hands with protective gloves.
2) In case of ingestion immediately seek medical
treatment.
3) In case of contact with skin or clothing immedi-
ately wash the affected area with clean water.
4) Do not mix different types of coolants. The mix-
ture can cause a chemical reaction with formation
of harmful substances.
3.2.4. Hydraulic Oil
2158
Only the quality hydraulic oil of power class under ISO 6743/ HV
(corresponds to DIN 51524, Part 3 HVLP; CETOP RP 91 H) must be
used for the Machine’s hydraulic system.
Fill the Machines with hydraulic oil of cinematic viscosity -
68 mm2/s at 40 °C (104 °F), i.e. ISO VG 68. This oil is most ap-
propriate for the use within the widest range of ambient tem-
peratures.
Note:
Hydraulic system is possible to be filled with synthetic oil which
during any leakage will be restless-degraded via microorgan-
isms found in water and soil.
Please, always consult with the oil pro-
ducer or dealer when switching to an-
other type of oil or when blending oils of
various brands together.
87
3.2. Media Specification

3.2.5. Oil – epicyclic transmission incl. 3.2.7. Brake Fluid

torque converter
2186 The fluid should comply with international specification of ISO
4925, SAE J 1703 f, DOT 3. It is miscible with brake fluids of all
brands that correspond with these specifications. Brake fluid is
Transmission can be filled alternatively with the following oils: designed for brake systems that operate at ambient tempera-
Mogul ATF II tures from –50 °C (–58 °F) to 60 °C (140 °F) and at operating tem-
Caterpillar TO-4 perature from –50 °C (–58 °F) to 205 °C (400 °F).

John Deere J20 C,D Note:

Military MIL-PRF-2104G As for the brake system, you may also use brake fluid that cor-
responds to international classification of DOT 4.
Allison C-4
General Motors Dexron II Equivalent

! CAUTION !
NEVER use engine oils, gear oils or DEXRON III. 3.2.8. Lube Grease
With normal ambient temperature, please use mul- 0787

ti-grade oil of low viscosity value 10W – 20 as if low-

grade oil 10W was used. If you use oil C-4 instead of Use plastic lubricant with lithium content to lubricate the Ma-
J20 then viscosity range not exceeding 10W, i.e. 10W chine under the following standards:
– 20, is recommended. Use J20C, D oil during exten- ISO 6743/9 CCEB2
sive fluctuation in temperatures. DIN 51502 KP2K-30
Synthetic oil has been approved to be used for trans- To lubricate the speed reduction transmissions, use the lubri-
mission if it corresponds to the abovementioned cant according to:
specifications. ISO 6743/9 BDHB2
Concerning ambient temperature characterized as DIN 51502 KP2N-25
TROPIC we recommend to use oil of SAE 30 viscosity
value that corresponds to the Caterpillar TO-4 per-
formance classification.

3.2.9. Windscreen Sprayer Liquid

2260

Use clean water up to 0 °C (32 °F) temperature when filling the

windscreen sprayer tank. We recommend to use water with
washing, antifreeze agent for motor vehicle windscreen spray-
ers at the ratio as per the Machine lubricating conditions – in CR
it is Glacidet K.

3.2.6. Gear Oil

2186 When hazard of temperature drop be-
low 0 °C (32 °F) exists then add antifreeze
Differential agent or drain water!
Use SAE 80W-90H API GL 5 or MIL-L-2105 B/C / LS oils to lubri-
cate hypoid differential.

Speed reduction transmission

Use SAE 85W-140H API GL 5 oils to lubricate down gearings.

3.2.10. Air-conditioning filling

2441

1 kg of coolant Halocarbon 134a

0.2 l of oil PAG 150
0.005 l of contrast medium

88 AP 240
3.3. Media MAINTENANCE MANUAL

Amount of Medium
Part Medium Type Brand
l (gal US)

Engine Engine oil as per Section 3.2.1. 7.0 (1.85)

2412

11.5 (3)
Engine Cooling liquid as per 3.2.3. amount during
exchange 2152

Fuel tank Diesel oil as per 3.2.2. 250 (66)

Hydraulic circuit Hydraulic oil as per Section 3.2.4. 22 (5.81)

2158

Oil in front axle disengaging Hydraulic oil as per 3.2.4. 3.5 (0.9)
2158

CLARK transmission Oil as per Section 3.2.5. 21.5 (5.7)

2186

Differential Gear oil as per Section 3.2.6. 6 (1.6)

2186

Speed reduction transmission Gear oil as per section 3.2.6. 2x5.2 (2x1.4)
2186

Brake system Brake fluid as per Section 3.2.7. 1.75 (0.46)

Lubrication according to Lubrication Chart Plastic lubricant as er Section 3.2.8. If required

0787

Sprayer Medium as per Section 3.2.9. 2.5 (0.66)

2260

Water tank for tyre sprinkling Water 460 (122)

596128

Air-conditioning Mixture according to chapter 3.2.10. -

2441

AP 240 89
3.4. Lubrication and Maintenance Chart

Every 20 hours of operation (daily)

3.6.1. Engine oil level check

3.6.2. Engine cooling liquid level check

3.6.3. Crankcase breather tube

3.6.4. Fan condition check and engine belt check

3.6.5. Air filter dust valve check

3.6.6. Hydraulic oil level check

3.6.7. Brake fluid check

3.6.8. Water tank refill

3.6.9. Water separator cleaning

3.6.10. Oil in the gearbox check

3.6.11. Warning and control devices check

3.6.12. Check of the front axle

After 50 hours of operation

3.6.42. Compressor check *

3.6.51. Check of wheel nuts for tightening *

Every 100 hours of operation (weekly)

3.6.13. Tyre pressure check

3.6.14. Check of the oil level in the front axle hydraulic cylinders

After 100 hours of operation

3.6.21. Gearbox oil filter replacement **

Every 250 hours of operation (3 months)

3.6.15. Engine oil change

3.6.16. Engine induction manifold and air filter sensor check

3.6.17. Battery check

3.6.18. Machine lubrication

After 250 hours of operation

3.6.34. Oil in differential change ***

3.6.37. Oil in rear axle change ***

90 AP 240
 MAINTENANCE MANUAL

Every 500 hours of operation (6 months)

3.6.19. Fuel filters replacement

3.6.20. Engine cooling liquid check

3.6.21. Gearbox oil filter replacement

3.6.22. Oil in differential and oil in rear axle check

3.6.23. Wiring check

3.6.24. Checking the air-conditioning coolant level

3.6.25. Air filter elements replacement

3.6.26. Filter of the cab ventilation replacement

3.6.27. Air filter of the air conditioning system replacement

Every 1000 hours of operation (1 year)

3.6.28. Brake shoes adjustment

3.6.29. KM nuts tightening check and front wheels lubrication

3.6.30. Hydraulic accumulator check

3.6.31. Engine belt check

3.6.32. Inspection of the air-conditioning compressor and air-conditioning belt

3.6.33. Gearbox oil change

3.6.34. Oil in differential change

3.6.35. Air drier replacement

Every 2000 hours of operation (2 years)

3.6.36. Valve clearance adjustment

3.6.37. Oil in rear axle change

3.6.38. Hydraulic oil and filter change

3.6.39. Oil in front axle hydraulic cylinders change

3.6.40. Brake fluid change

3.6.41. Engine cooling liquid change

3.6.42. Compressor check

3.6.43. Air conditioning system check

AP 240 91
3.4. Lubrication and Maintenance Chart

Maintenance if required

3.6.44. Water from separator draining

3.6.45. Fuel system venting

3.6.46. Coolers cleaning

3.6.47. Refilling the oil level in the front axle hydraulic cylinders

3.6.48. Sprinkling filter cleaning

3.6.49. Brush scrapers cleaning

3.6.50. Machine cleaning

3.6.51. Check of wheel nuts for tightening

3.6.52. Air collector inspection

3.6.53. Charging of the battery

3.6.54. Screw connection tightening check

* First after 50 hours

** First after 100 hours
*** First after 250 hours

92 AP 240
3.5. Lubrication and Service Plan MAINTENANCE MANUAL

LUBRICATION AND SERVICE PLAN

INSPECTION

LUBRICATE

EXCHANGE

2000
2
1000

500 2

1 1
250

20
Filter set 2000 h / 4-760136

Filter set 1000 h / 4-760135

Filter set 500 h / 4-760016

Filter set 250 h / 4-760134

1 1

Engine oil: SAE 15W/40, API CI-4, CH-4

1 Fluid for automatic transmision see chapter 3.2.5.
2 Transmission oil: SAE 80W-90H API GL-5
3 Transmission oil: SAE 85W-140H API GL-5

Hydraulic oil: ISO VG 68 ISO 6743/HV

1 Grease: ISO 6743/9 CCEB 2
2 Grease: ISO 6743/9 BDHB 2

374105en

AP 240 93
3.6. Lubrication and Maintenance Operations
Carry out lubrication and maintenance in regularly repeated in-
tervals as per the everyday data reading on the counter of hours
actually worked.

0 RPM 28°C
ENG RPM COOL TEMP

20% 100
FUEL LEVEL ENG HRS

396313A

This Manual states only the basic information about the engine, others are in the Engine Operating & Maintenance Manual, supplied
together with the machine as part of its documentation.

Follow also the instructions given in the engine operation and maintenance manual!

Carry out maintenance with the Machine placed on flat, paved surface, and secured against any self-
motion, always with the engine OFF, key removed from ignition box, and with the wiring disconnected
(unless otherwise required).

! CAUTION !
Removed or loose bolts, plugs, threaded joints of the hydraulics, etc. shall be tightened with the torque according
to the Tables in Section 3.6.54., unless a different value is given with the relevant operation.

Have the air tank inspected by a specialized service company no later than every 5 years. Make sure the
inspection date and the service engineer sign are marked on the label. NO welding or heat treatment are
admissible on the air tank. The air tank life is max 40 years, it shall be discarded afterwards.

Following the first 50 hours of operation of the new Machine (following a major overhaul) carry out as per:
3.6.42. Compressor check
3.6.51. Check of wheel nuts for tightening

Following the first 100 hours of operation of the new Machine (following a major overhaul) carry out as per:
3.6.21. Gearbox oil filter replacement

Following the first 250 hours of operation of the new Machine (following a major overhaul) carry out as per:
3.6.34. Oil in differential change
3.6.37. Oil in rear axle change

94 AP 240
 MAINTENANCE MANUAL

Every 20 hours of operation (daily)

3.6.1. Engine oil level check

• Shut off the engine, wait ca 3 min for oil to descend into
crankcase sump.
• Pull out oil dipstick, wipe it, put it back and pull out again to
read oil level.
• Maintain level between division lines stamped on oil dip-
stick. LOW division mark shows lowest possible oil level,
HIGH division mark shows the highest one.

Version 1:

374044

Version 2:

Note
The engines are delivered by the manufacturer in two versions,
which differ in the location of the oil filter and oil gauge rod.

430007

• Replenish oil via filler neck.

! CAUTION !
Refill oil of identical type, use oils as stated in
Section. 3.2.1.

Do NOT run the engine unless there is cor-

rect oil level in the engine.
374045

AP 240 95
3.6. Lubrication and Maintenance Operations
3.6.2. Engine cooling liquid level check

• Check cooling liquid level with the engine at rest, cooled

down below 50 °C (120 °F), maintain this level between
”MIN” and ”MAX” marks.

374081

Wait to remove the filler plug only after

engine coolant temperature drops below
50 °C. If filler plug is removed at higher
temperature then there is hazard of va-
pour scald or cooling liquid scald due to
inner overpressure effect.

! CAUTION !
Top up cooling liquid the composition of which is
given in Section 3.2.3.
Do NOT use any additives in the engine cooling liq-
uid to eliminate cooling system leakage!
Do NOT refill cold coolant into hot engine! Danger of
engine castings damaged.

3.6.3. Crankcase breather tube

• Check the outlet is not clogged with deposits.

374072

96 AP 240
 MAINTENANCE MANUAL
3.6.4. Fan condition check and engine belt
check

• Inspect visually cooling air blower. If for example you find

missing part of the material, cracks, shape changes, etc. –
please replace the cooling air blower.

374047

• Inspect visually the belt. If longitudinal cracks, or smooth,

bright flats occur on the belt, or belt edges are shattered,
or there are extracted parts of material, then the belt must
be adjusted or replaced, refer to Section called “Belt tension
after 1000 hours”.

Belt
Order number: 1287632

374048
347048

AP 240 97
3.6. Lubrication and Maintenance Operations
3.6.5. Air filter dust valve check

• Any dust trapped will automatically be emptied during Ma-

chine operation. We recommend to occasionally clean the
exit slit, press to remove any dust trapped.

Replace the dust valve immediately if it is

damaged!

Dust valve
Order number: 1-952454
374049

2
3
• Should the Machine be fitted with air pre cleaner, clean the
vessel (1) when filled with dirt up to the mark, first unscrew 1
nut (2) and remove cover (3).

374050

3.6.6. Hydraulic oil level check

• Open oil tank cover. Check and maintain oil level. Pilot lamp
will indicate any oil loss below STOP (engine stops).

MAX

MIN
STOP

! CAUTION !
Engine can be started only after oil is filled up. Fill
up with the same type of oil via filling device, refer
to Section called “Oil Exchange“.
374092A
374051

98 AP 240
 MAINTENANCE MANUAL
3.6.7. Brake fluid check

• Keep its level between ”MIN” and ”MAX”. Clean filler cap and
filler neck before filling up.

374052

• Check the following when fuel has dropped:

Pipes and hoses of the system
Connection tightness
brake master cylinder
brake cylinders in rear axle wheels

Keep brake fluid in its original, well

closed containers! When it is to be used,
please follow instructions of brake fluid
producer.

Brake fluid will cause damage to painted

parts of the Machine.

When filling up, avoid and fluid spilled

over the Machine or outside the Machine.

AP 240 99
3.6. Lubrication and Maintenance Operations
3.6.8. Water tank refill

• Open the cap and fill up with clean water.

374083A

3.6.9. Water separator cleaning

• This should be performed with the full air pressure in the

air reservoir (according to the brake circuit pressure gauge).
Shut OFF engine, switch ON parking brake. Pull drain valve’s
chain to confirm valve operation is OK.

374N026

100 AP 240
 MAINTENANCE MANUAL
3.6.10. Oil in the gearbox check

! CAUTION !
Check with the engine idling at oil temperature of
82÷93 °C – best after Machine operation is ended.

• Open and lift off the cover between pedals on Machine’s

floor.

374082

• Unscrew and pull out dipstick, wipe off and push in again.
Pull it out once more and check oil level – it must reach the
upper gauge line.
• Fill up oil using this neck and screw the oil level gauge back.

374055

AP 240 101
3.6. Lubrication and Maintenance Operations
3.6.11. Warning and control devices check

• Turn ON the switches to test that lights, warning lamps, traf-

fic indicator lights, flashing beacon.

0
I
II

III

IV

374056A

• Turn ignition key to position ”I” (confirm travel controllers

are in idle position [neutral], parking brake switched ON),
pilot lamps for recharging, idle position, parking brake must
light up. Check Power View display and horn.
0
I
II

III
F
1 IV

2 N

3 R

START START
3236

I
3236

P 0

START

374057A

• Start the engine, pilot lamp for recharging must go off,

check engine oil pressure via the display. Press the emer-
gency brake button – the engine stops.
2000 50°C
ENG RPM COOL TEMP

1 bar 100
OIL PRESS ENG HRS

II

374058A

• Start the machine according to the respective instructions

in the Operating Manual. When turning off the parking
brake switch, make sure that the brake pilot lamp turns off.
When driving off, make sure that the respective pilot lamp
of the activated place turns on and whether the neutral pilot
lamp turns off.

F
1
2 N

3 R

374059A

102 AP 240
 MAINTENANCE MANUAL
• Shut OFF the engine, try the pilot lamp for brake failure.
“Floor” the brake pedal repeatedly several times to lower air
pressure in line with pressure gauge to 5.2 bar – pilot lamp
for brake failure must light up and alarm signal be heard.

374060A

When in operation, check continuously

the instruments and pilot lamps.

Use acoustic alarm to warn engine will

start, confirm there is no hazard for any-
body when engine starts.

AP 240 103
3.6. Lubrication and Maintenance Operations
3.6.12. Check of the front axle

Regularly check the condition of the front

axle. A failure of the front axle, especia-
lly the axle hydraulic suspension system,
has an adverse effect on the braking
efficiency.

• Visually check the height of the front of the machine fra-

me above the tyres. The height of the frame side above the
wheels should be at least 100 mm on each side.
435123

435124

• If the height is smaller, visually check the axle for leaks and
the condition of the chrome parts of the piston rods – he-
ight of the wiped surface (at least 25 mm on each side).
• If an oil leak is detected, do not operate the machine until
the fault has been rectified and the oil has been refilled.

435125

It is forbidden to operate the machine

with the wrong amount of front axle
charge.

104 AP 240
 MAINTENANCE MANUAL

Every 100 hours of operation (weekly)

3.6.13. Tyre pressure check

• Check the pressure in tyres inflated as required for operation

depending on values in the Table when cold (before driv-
ing) at temperatures of 18÷21 °C (64.5÷70 °F). Connect the
tyre inflation hose to the adaptor mounted instead of tyre
inflating valve with standard version of the Roller (pressure
gauge complete with inflation hose is included in the Ma-
chine equipment).

When inflating, check the following: 374061

Valve, and whether it has protective
cap.
Outer condition of tyres, whether
not damaged (due to local deforma-
tion, part of rubber separated, cracks,
fissures).

Contact area and effective load depending on the wheel load and tyre inflation

CONTACT AREA (cm2)

Load per one wheel (kg)

11.00-20 / 18 PLY Compactor without pattern
1300 1500 2000 2500 3000
3 409 442 531 605 688
4 385 416 495 570 642
5 358 390 464 537 600
Tyre inflation (bar)
6 334 364 434 507 560
7 311 345 425 496 541
8 292 328 399 463 512
Machine weight (kg) 10400 12000 16000 20000 24000

EFFECTIVE LOAD (kg/cm2)

Load per one wheel (kg)

11.00-20 / 18 PLY Compactor without pattern
1300 1500 2000 2500 3000
3 3.18 3.39 3.77 4.13 4.36
4 3.38 3.61 4.04 4.39 4.67
5 3.63 3.85 4.31 4.66 5.00
Tyre inflation (bar)
6 3.89 4.12 4.61 4.93 5.36
7 4.18 4.35 4.71 5.04 5.55
8 4.45 4.57 5.01 5.40 5.86
Machine weight (kg) 10400 12000 16000 20000 24000

AP 240 105
3.6. Lubrication and Maintenance Operations
3.6.14. Check of the oil level in the front axle
hydraulic cylinders

• Shut down the machine on a flat and solid surface where

there is no potential natural hazard (landslides, possible flo-
oding, etc.)
• Measure the reference dimension of 291 mm on both piston
rods of the front axle.
• If the measured dimension is less than 260 mm, search for
the location and cause of the oil leak and rectify the fault.
• Refill oil according to Chapter 3.6.47.

435126

It is forbidden to operate the machine

with the wrong amount of front axle
charge.

106 AP 240
 MAINTENANCE MANUAL

Every 250 hours of operation (3 months)

3.6.15. Engine oil change

Drain oil when it is still hot after operation

is ended, or while running, warm up the
engine until cooling liquid reaches 60 °C.
Observe fire precautions!

Beware of hot oil burn hazard when drain-

ing oil. Let oil cool down below 50 °C.

• Remove drain plug and let oil flow out into a vessel of ca 9 l
(9.5 qt) capacity. Reinstall drain plug. Apply 80 Nm (59 lb ft)
torque to tighten.

374062A
374062

• Clean oil filter and its vicinity. Remove filter.

Version 1:

374063

Version 2:

Note
The engines are delivered by the manufacturer in two versions,
which differ in the location of the oil filter and oil gauge rod.

Engine oil filter

Order number: 4-9501000307

430006

AP 240 107
3.6. Lubrication and Maintenance Operations
• Apply oil slightly across filter gasket.

• Clean contact surface for filter gasket. Screw on the filter

and tighten properly with hand.

Do not tighten excessively the filter, its

thread and gasket may get damaged.

Note:
Refer to Engine Operation and Maintenance Manual for the spe-
cial spanner required.
396247

• Use filler neck to fill the engine – medium amount is 7 l

(7.4 qt).

374045

• Fill to upper gauge line of the dipstick.

• When exchanged, start the engine for 2 - 3 min. Check tight-
ness of drain plug and filter. Stop the engine and wait for
5 min until oil flows down to crankcase sump. Then use dip-
stick to confirm oil level.

Exchange oil after 3 months at the latest 400178

even though 250 hours have not been ac-
tually operated. Exchange oil within inter-
val that occurs as first.
In case of work in a very dusty environ-
ment, shorten the engine oil replacement
intervals.
Use recommended filters, refer to
Catalogue of Spare Parts.
Use oil as per Section 3.2.1.

Drain oil into catch vessels.

Spent oil and filter are ecological waste –
hand over for disposal.

108 AP 240
 MAINTENANCE MANUAL
3.6.16. Engine induction manifold and air filter
sensor check

• Check pipe hoses and fixing of clips.

374081A

374065
374098

• Check air filter cuff. Cover suction hole.

374066

• Start the engine, increase engine speed to max, check if pi-

lot lamp lights up.

II

374067A

AP 240 109
3.6. Lubrication and Maintenance Operations
• Unless it lights up, check vacuum switch (1), pilot lamp on
dashboard, wiring.

374066A

Do NOT operate the Machine if induction

manifold, air filter cuff are damaged!

110 AP 240
 MAINTENANCE MANUAL
3.6.17. Battery check

• Use isolating switch to disconnect storage batteries.

3351

0 30 sec

I 0

374012А

• Open the cover.

374017

• Clean the surface of batteries.

• Check the condition of poles and terminals (1). Clean bat-
tery poles and terminals. Apply a thin layer of grease to ter-
minals (make sure that the contact is good).

374069

MAINTENANCE-FREE BATTERY
• In case of a maintenance-free battery (the battery has no
freely accessible plugs), only the no-load voltage on ter-
minals is checked. The batteries cannot be replenished. If
the no-load voltage is 12.6 V and more, the battery is fully
charged. If the no-load voltage is below 12.4 V, the battery
should be charged immediately. After the battery is char-
ged, leave it to stand for 2–3 hours and then measure the
voltage again. It is recommended to be mounted 24 hours
after charging.
Note:
The no-load voltage is the voltage measured at the terminals of
the battery which was at rest for at least 12 hours – was neither
charged nor discharged.

AP 240 111
3.6. Lubrication and Maintenance Operations
! ATTENTION !
Unless the Machine is going to be used during se-
vere frosts, remove storage batteries and store them
so to be protected against any frost. While stored,
inspect their charging condition 1x per month and
recharge.
112
Keep storage batteries dry and clean.
NEVER disconnect storage battery with
the engine running. Always follow stor-
age battery manufacturer’s manual when
working with the storage battery!
Use rubber gloves and safety glasses
when handling storage battery.
Protect your skin with proper clothing
against being stained by electrolyte.
Upon eye contact with electrolyte imme-
diately flush eyes with large amounts of
water for at least a couple of minutes. Get
prompt medical attention.
Upon ingestion of electrolyte drink max
amount of milk, water or solution of cal-
cined magnesia in water. Get prompt
medical attention.
Upon skin contact with electrolyte re-
move contaminated clothing, including
shoes, wash affected spots as soon as pos-
sible with soap water or solution of soda
and water. Get prompt medical attention.
Do not eat, drink, smoke, while at work!
Upon work completion, please wash your
hands and your face thoroughly with wa-
ter and soap!
Do NOT attempt to confirm a wire is ener-
gized through contacting Machine frame.
Disconnect storage battery before its re-
pair or when handling wires or electric
equipment within wiring circuit to avoid
any short-circuit.
To disconnect storage battery you must
first disconnect (–) pole of the cable. To
connect, first connect (+) pole. NEVER
attempt to make direct conductive con-
nection between storage battery’s both
poles, short circuit will occur with the risk
of storage battery explosion.
Do not turn storage battery upside down,
electrolyte may pour down from the de-
gassing plugs.
Flush with water and neutralize with lime
the spot affected with spilled electrolyte.
Hand over the aged storage battery that
does not work, for its disposal.
AP 240
 MAINTENANCE MANUAL
3.6.18. Machine lubrication

• Lubricate with grease as per Section 3.2.8.

• Remove floor coverings to make lubrication points acces-
sible.

374018A

• Lubricate pin (1). If lever (2) is overhead the horizontal posi-

tion when braked, then reposition pin (3) into another hole
of pull rod (4).

Be careful grease does not get onto active

surface of brake disc! 4
1
2

3
374041A
374041B

Shaft joints

374076

Steering pins

374180

AP 240 113
3.6. Lubrication and Maintenance Operations
Bonnet hinges

374077

Door hinges

374078

Cover suspensions.

374108

Edge cutter pins.

374109

114 AP 240
 MAINTENANCE MANUAL

Every 500 hours of operation (6 months)

The set of filters after 500 operating hours can be

ordered under the order number 4-760016. For the
list of all spare parts, see the table in the end of this
publication.

3.6.19. Fuel filters replacement

• Clean and remove filter.

374079

• Clean seating face for filter.

396249

• Apply oil on sealing ring.

396247

AP 240 115
3.6. Lubrication and Maintenance Operations
• Fill up the new filter with clean fuel.

Fuel filter
Order number: 4-9501000308

396248

• Install filter and tighten properly with hand – as per filter

manufacturer’s data (by 2/3 of revolution once filter is seat-
ed properly).

396250A

• Disconnect water separator sensor connector, and proceed

the same like in previous text, connect sensor once replaced.

Fuel filter
Order number: 1194061

Note:
Small amount of air that gets into the system during filter re-
374080
placement will automatically deaerate if the replacement pro-
cedure described has been adhered to. Unless filters are filled
with fuel, deaerate the system according to Section called “How
to deaerate fuel filter”.

Use original filters required, refer to Spare

Parts Catalogue.
Do NOT tighten filters using force, the
thread and gasket may get damaged.

Collect fuel flowing out!

NEVER smoke when at work, replace in
Store spent filters in separate containers
well-ventilated rooms with no fire hazard.
and hand them over for their disposal.

116 AP 240
 MAINTENANCE MANUAL
3.6.20. Engine cooling liquid check

• Inspect cooling liquid concentration with the refractometer

using cold engine.

Check always before winter season.

Unless concentration for ambient tem-
peratures of -36 °C (-33 °F) is found, adjust
it or exchange cooling liquid according to
Section 3.2.3.

374081B

AP 240 117
3.6. Lubrication and Maintenance Operations
3.6.21. Gearbox oil filter replacement

First carry out after 100 hours.

• Open the cover in the floor.

374082

• Unscrew oil filter, collect oil flowing out. Apply oil over new
filter’s packing ring. Screw on the new filter and tighten with
27 – 34 Nm (20 – 25 lb ft) torque.

Oil filter
Order number: 4-9502000402

374055B

Use only CLARK filters recommended.

Do NOT tighten with force, danger of
threads and gasket damaged.

Let gearbox cool down below 50 °C before

replacing.

Spent filter is ecologically hazardous

waste, hand over for disposal.

118 AP 240
 MAINTENANCE MANUAL
3.6.22. Oil in differential and oil in rear axle
check

• Clean and unscrew inspection plug for differential. Check oil

level is up to inspection hole.
• If it is required to fill up the oil, proceed according to Chapter
3.6.34. Axle drive oil change.
• Tighten the plug with 80÷90 Nm (59÷66.4 lb ft).

374090

• Clean and remove plug on rear side of down gear housing,

and check if level reaches up to the inspection hole or flows
out slightly.
• If it is required to fill up the oil, proceed according to Chapter
3.6.37. Rear axle oil change.

374085

3.6.23. Wiring check

• Check for any damage to cables, connectors, protective

hoses, and their fastening, especially if in the vicinity of hot
surfaces and moving parts of the machine including the en-
gine. Replace damaged parts. Use only original spare parts.

AP 240 119
3.6. Lubrication and Maintenance Operations
3.6.24. Checking the air-conditioning coolant
level

• Remove cover.

374K01

• Check the filter dehydrator sight hole while the air condi-
tioning system is on and the engine is running at idle speed.

374K02

• The liquid flowing in the sight hole must be transparent.

OK

402D285

• Fogging or foam indicates the lack of coolant and, thus, de-

creased unit functionality. Check the hoses, their connec-
tions, and the compressor for coolant leaks.
• To remove any defects, call an authorised service company.

402D284

120 AP 240
 MAINTENANCE MANUAL
3.6.25. Air filter elements replacement

Note:
The air filter contains the main and safety cartridge. Replace fil-
ter elements after the air filter fouling pilot lamp (32) is lit and no
later than after each 500 engine hours.

Manufacturer does not recommend any

I
II

III

IV

cleaning of the element due to lowered

filtration capacity by up to 40 % and due
to potential of damaging the element
when being cleaned.

430105

• Slacken the clips and take off the lid.

374081C

• Replace the main cartridge.

Air filter element

Order number: 4-5358520127

374101

• Replace the safety element.

Air filter element

Order number: 4-5358520128

374102

AP 240 121
3.6. Lubrication and Maintenance Operations
• Take off dust valve, clean it and reinstall.

Dust valve
Order number: 1-952454

374081D
NEVER clean inner space of the filter with
pressure air to avoid any dust penetrating
into engine induction manifold.
Use original elements, only.
When washing the Machine be careful not
to splash water into air filter.
Replace the dust valve immediately if it is
damaged!
Do NOT operate Machine with filter body
damaged or filter cover damaged.
In case of work in a very dusty environ-
ment, shorten the filter element replace-
ment intervals.

122 AP 240
 MAINTENANCE MANUAL
3.6.26. Filter of the cab ventilation replacement

• Remove the cover (1). Replace the filter cartridge (2) (sucked
air filtration outside the cab).

Filter element
Order number: 4-612104

Note: 2
Clean (dust, blow out) once a month. When working in a dusty 1
environment, shorten the cleaning intervals.

374035C

• Remove the cover. Replace the filter cartridge (sucked air fil-
tration from inside the cab).

Filter element
Order number: 4-5351010189

374015

• Dismount the water tank.

430106

• Remove the cover. Replace the filter cartridge.

Filter element
Order number: 4-5351010189

430107

AP 240 123
3.6. Lubrication and Maintenance Operations
3.6.27. Air filter of the air conditioning system
replacement

• Remove the cover grille on both sides.

374K03

• Replace both filter elements.

• Beat the elements gently and wash them in a detergent so-
lution. Should any element be damaged or should it not be
possible to remove dirt, replace it with a new one.
• In case of work in a highly dusty environment, shorten the
intervals of cleaning.

Filter
Order number: 4-16481

374K04

124 AP 240
 MAINTENANCE MANUAL

Every 1000 hours of operation (1 year)

The set of filters after 1000 operating hours can be

ordered under the order number 4-760135. For the
list of all spare parts, see the table in the end of this
publication.

3.6.28. Brake shoes adjustment

Brake off the Roller before wheel removal

• Lift a bit the Machine onto the rear lugs of the frame so the
rear wheels do not touch the ground. Chock the rear part of
Machine frame. Secure front wheels with Scotch blocks on
both sides.

374086

• Remove tyre inflating and blowing off hose (1). Remove

wheels.

374152

• Remove step by step the brake drums. When removal is

complicated, use forcing-off screws M12-60 of min. 8G
strength, into holes (1) of brake drum (2). Confirm there are 1
no scratches or cracks across drum’s internal diameter.
1

1
1
374N121

AP 240 125
3.6. Lubrication and Maintenance Operations
• Check thickness, uneven wear or contamination of lining (1).

1 2 1

374N122

If, while checking, you find lining thick-

ness is 4 mm (0.16”) or smaller, please
check lining after next 500 operating
hours.
Replace lining always when thickness
reaches min value of 2 mm (0.08”).
Replace all brake clips at one time to
maintain uniform braking!
Always replace adjusting mechanism de-
fected with new one.
When replacing, use original brake clips
only!

With brake shoe lining replaced the brake

efficiency will lower and stopping dis-
tance will get longer. Adapt driving mode
and braking mode to this case!

• Check brake cylinder for any leakage of brake fluid.

374N123

126 AP 240
 MAINTENANCE MANUAL
• When checking is completed reinstall the drums. Turn brake
drum with its adjustment hole pointing downward towards
adjusting wheel. Rotate adjusting wheel (1) until brake clips
lean against brake drum (brake drum unable to rotate). Turn
a bit the adjusting screw backward by only such turn so the
brake clips get released (brake drum able to rotate freely).

1
374N121A

Carry out brake clip adjustment during:

Insufficient brake efficiency (long step of
brake pedal)
Replacement of worn clips for new ones
Following the installation of new brake
drum or after brake drum’s inner diameter
is machined (refer to Workshop Service
Manual).

• Before installing wheels onto the brake drums following

the brake repair, please point the brake drum bolts against
holes in the wheels using an appropriate lever so to avoid
damage of bolt threads, reinstall wheels, tighten wheel nuts
with 400 Nm (295 lb ft) torque.

AP 240 127
3.6. Lubrication and Maintenance Operations
3.6.29. KM nuts tightening check and front
wheels lubrication

• Check the tightening of KM nuts of front wheels applying a

torque of 250 Nm.

374072C

• Lubricate with grease as per Section 3.2.8.

- External bearings of front wheels

374072B

- Internal bearings of front wheels

374075

• In order to grease the inner and outer bearings of front axle

wheels thoroughly, the lubricating grease must be pressed
out around the flange.

430023

128 AP 240
 MAINTENANCE MANUAL
3.6.30. Hydraulic accumulator check

• Remove floor covering.

374018B

• Let filling pressure of 120 bar (on nameplate) be checked

and made up by authorized service department.. Call your
dealer if required.

374076A

When operating the Roller at the tem-

peratures constantly over 50 °C lower the
checking interval to ½ the year.

AP 240 129
3.6. Lubrication and Maintenance Operations
3.6.31. Engine belt check

• With the engine running, check visually the pulley of alter-

nator, cooling air blower, crank shaft, to confirm these do
not oscillate.

374087

• Stop the engine! Check belt tension.

374048
347048

• Press belt with hand in the longest spot between pulleys (30
cm) with ca 110 N (25 lb) force, refer to the Fig. If slack X is
higher than belt thickness, tighten the belt.

Note:
Please, measure accurately belt tension using a fixture possible
to order with CUMMINS Company in line with Engine Mainte- X
nance Manual (Section V15) which is part of Machine documen-
tation.

0N
11 lb
25

374089

• Tighten the belt after you have slackened bolt for alternator
holder (1), tensioning arm (2), by tilting out the alternator 2
away from the engine, refer to the Fig. Tighten bolt (1) with
66 Nm (49 lb ft) torque, tighten bolt (2) with 31 Nm (23 lb ft)
torque. Replace belt following its slackening, by tilting the
alternator back to the engine.

374048A
347048

130 AP 240
 MAINTENANCE MANUAL
3.6.32. Inspection of the air-conditioning
compressor and air-conditioning belt

• Check the strength of the compressor attachment and the

compressor bracket. Make sure that the belt does not spin. If
necessary, tighten the screws.
• Inspect visually the belt. If longitudinal cracks, or smooth,
bright flats occur on the belt, or belt edges are shattered, or
there are extracted parts of material, then the belt must be
adjusted or replaced.

Belt
Order number: 4-6160120097
374K05

AP 240 131
3.6. Lubrication and Maintenance Operations
3.6.33. Gearbox oil change

Drain oil when operation has ended after

cooling down to 50 °C, or while driving
you wait until oil warms up.

Beware of burn hazard when draining hot

oil .

• Remove plug, drain oil to a prepared vessel of 21.5 l (5.7 gal

US) and at the same time replace filter as per Section named
374062B
“How to Replace Filter”.

• Open the cover underneath control panel.

374082

• Pour the amount of 21.5 l (5.7 gal US) through a hole after
having pulled out check dipstick, up to FULL mark. Start the
engine and while idling, check oil level to confirm it reaches
up to ADD mark. With oil warmed up to 82÷93 °C, please
check and fill up to FULL if required.

374055

Observe fire precautions!

Use recommended oils according to
Section 3.2.5.

Drain oil into collection vessels.

Spent oil is ecological waste – hand over
for disposal.

132 AP 240
 MAINTENANCE MANUAL
3.6.34. Oil in differential change

First carry out after 250 hours.

• Drain sprinkling tank, refer to Section called “How to clean

sprinkling filter”. Remove the tank.

374083

• Remove filler plug (1) and inspection plug (2).

374084A

• Let the oil drain into the prepared vessel.

• Use hole (1) to pour 6 l (1.58 gal US) of oil according to Sec- 374090A
tion 3.2.6.
• Check oil level in hole (2). Oil must pour out slightly.
• Tighten inspection plug (2) with 80÷90 Nm (59÷66 lb ft)
torque. Tighten filler plug (1) with 70÷80 Nm (52÷59 lb ft)
torque.
1

Beware of burn hazard when draining hot

oil.

2
Drain oil into collection vessels. Spent
oil is ecological waste – hand over for
disposal.
374084A

AP 240 133
3.6. Lubrication and Maintenance Operations
3.6.35. Air drier replacement

• Remove floor covering.

374018B

• Remove the water separator cartridge. Clean the upper

part of the body. Apply oil on the packing of the new water
separator cartridge. Tighten the cartridge by hand – torque
15 Nm (11 lb ft).

Filter element
Order number: 4-5358060018

374091

If you detect oil marks on the water

separator cartridge, inspect the deliv-
ery piping of the compressor; see Chap.
Compressor inspection.

The used water separator cartridge is

an ecological waste – hand it over for
disposal.

134 AP 240
 MAINTENANCE MANUAL

Every 2000 hours of operation (2 years)

The set of filters after 2000 operating hours can be

ordered under the order number 4-760136. For the
list of all spare parts, see the table in the end of this
publication.

3.6.36. Valve clearance adjustment

• Please, contact your regional CUMMINS representatives,

refer to “Engine Operation And Maintenance Manual” (sup-
plied with the Machine), or your dealer.

3.6.37. Oil in rear axle change

First carry out after 250 hours.

2
• Clean and remove drain plugs (1), filling plugs (2) – in both
housings.
• Let the oil drain into the prepared vessel. After draining the
oil, mount the plugs (1).
• Fill 5.2 l (1.4 gal US) of the new oil according to Chapter 3.2.6 1
into the filler (2) for each housing separately. The oil can run
out slightly from the hole (2). 374085A
• Remount the filler plug (2).

Beware of burn hazard when draining hot

oil.

Drain oil into collection vessel of 6 l (1.6

gal US) capacity.
Spent oil is ecological waste – hand over
for disposal.

AP 240 135
3.6. Lubrication and Maintenance Operations
• Remove the housing cover on both speed-reduction trans-
missions using unloading screws.

Right side

374166

Left side

374167

• Lubricate the cover with Vaseline according to Chapter 3.2.8.

• Remount the cover.

374168

136 AP 240
 MAINTENANCE MANUAL
3.6.38. Hydraulic oil and filter change

Exchange oil before season or following a

long term shutdown of the Machine.
Drain oil when operation has ended after
cooling down to 50 °C, or while driving
the Machine, wait until oil warms up.
Observe fire precautions!

Beware of burn hazard when draining hot

oil.

• Open the cover and drain 22 l (5.81 US gal) of oil via the
valve. When drained, close the valve.

374051A

• Remove the cover.

374093

• Disconnect sensor for filter (1) clogged, remove filter cover

(2). 1
2

374094

AP 240 137
3.6. Lubrication and Maintenance Operations
• Replace filter element.

Filter element
Order number: 1276829

Replace the filter element always after

the control lamp of the hydraulic oil filter
clogging lights up, if the minimum opera-
tion temperature of oil of 50 °C (140 °F) is
reached.

374096

• Disconnect oil level sensor (3), remove pipe hoses (4) and (5)
and cover (6), clean tank interior.

6 3
5

4
374094A

• Remove suction strainer, wash and blow out strainer with

pressure air from inside. Check condition of suction strainer,
in case of any damage to filtration part, replace the strainer.
Use new gasket under the cover (6).
6
Suction strainer
Order number: 4-5451050018

Sealing tape
Order number: 4-5422250006

374095

138 AP 240
 MAINTENANCE MANUAL
Temperature sensor inspection
• Remove the sensor. Put in liquid heated to 88 °C (190 °F)
temperature and check whether pilot lamp for oil overheat-
ing will light up.

Temperature sensor
Order number: 4-5503580053

374097

Filling the hydraulic circuit:

• Fill using the hydraulic unit.
• You can order the hydraulic unit from the machine manufa-
cturer.

Hydraulic unit 230 V

Order number: 1251998

Hydraulic unit 110 V

Order number: 1255297

Note:
The hydraulic unit 230 V is intended for operation in 230-Volt 1251998
networks (Europe), the hydraulic unit 110 V is intended for ope-
ration in 110-Volt networks (North America).

• Put the quick-release coupling of the hydraulic unit on the

filling quick coupling.

374065A

• Fill oil up to max level.

MAX

374051B

AP 240 139
3.6. Lubrication and Maintenance Operations

Use alternative way of filling or refill-

ing via filler neck on the tank only in
emergency!
When using this filling method, reduce
the next change interval to the half, i.e.
1000 hours or 1 year.

Insert
Order number: 4-5358520154

374094B

Observe cleanliness during work. Avoid

any contamination of the system with
materials that might cause damage to the
units!
To clean the tank use cleaners with no fi-
bre let-off, do NOT use chemical cleaners.
Use recommended filters, refer to Spare
Parts Catalogue.
Use only recommended oil according to
Section 3.2.4.
Exchange oil and filter always when de-
struction of internal parts of the units (hy-
dromotors, hydrogenerators) occurs, or
following a major repair of hydraulic sys-
tem. Clean suction strainer and hydraulic
tank. Fill new unit with oil before its in-
stallation. Test the Machine function with
the engine running at high speed. Check
tightness.

Blind all holes with plugs when hydraulic

circuits are disconnected.
Collect drained oil and do not let it soak
into ground.
Spent oil and filters are ecologically haz-
ardous waste – hand it over for disposal.

140 AP 240
 MAINTENANCE MANUAL
3.6.39. Oil in front axle hydraulic cylinders
change

• Use front lifting lugs to lift a bit the front part of the Roller so
its front wheels get relieved by means of crane, or use hand
jack behind front wheels.

374099

• Remove cover.

374077A

• Remove fast coupling on the pipe that connects hydraulic

cylinders for front axles, put on the hose, and descend the
Machine slowly to drain oil into a vessel set up. Screw in the
filling quick-coupling, refill the hydraulic cylinders using a
filler with new oil to the reference dimension.

37459

Observe fire precautions!

Use recommended oil as per Section 3.2.4.

Spent oil is ecological waste – hand over

for disposal.

435122

AP 240 141
3.6. Lubrication and Maintenance Operations
3.6.40. Brake fluid change

! CAUTION !
To deaerate, there must be air pressure level inside
brake system (air tank). Unless there is air level the
system must be filled while the engine is running –
follow safety measures during engine start.
Two persons must work together to carry out
deaeration.

Pump out brake fluid from the circuit:

• Remove rear wheel according to Section called 3.6.28. Brake
shoes adjustment.
• Slip box end wrench over the hose pipe No. 9.

374N138

• Slip hose pipe incl. key over the deaeration (air relief ) screw.

374N139

• Locate hope pipe in the vessel and slacken deaeration screw

for brake cylinder. It is possible to always handle the wheel
couple simultaneously. Second person is to depress brake
pedal repeatedly to force out fluid step by step from all
brake cylinders into the vessel. Tighten deaeration screw.

374N140

142 AP 240
 MAINTENANCE MANUAL
• Fill equalizer tank with fluid and keep level above ”MIN”
when deaerating.

374052

• Slacken deaeration screw at the brake master cylinder by 2

turns, and when filled up with fluid, close deaeration screw.

374100

• Fill tanks with new brake fluid (immerse hose pipe end
below level). Slacken deaeration screws. Press brake pedal
slowly as long as fluid moves out with air bubbles. Then with
the brake pedal pressed, close deaeration screws for brake
cylinders, wipe them and install protective caps. Check cir-
cuit tightness, level in the tank, and adjust. Reinstall wheels.
Tighten wheel nuts with 400 Nm (295 lb ft) torque.

Keep brake fluid inside original, well

closed containers! When in use, pro-
ceed according to brake fluid producer’s
instructions.

Brake fluid will damage painted parts of

the Machine.
Use recommended brake fluid under
Section 3.2.3.

When filling up, avoid fluid spilled over

the Machine and off the Machine as well.
Collect brake fluid in the vessel and hand
it over for disposal!

AP 240 143
3.6. Lubrication and Maintenance Operations
3.6.41. Engine cooling liquid change

! CAUTION !
Drain liquid when operation is finished, and when
driving the Machine, wait until liquid warms up to
80 °C (176 °F) temperature.

• Take off the lid from equalizer tank.

374081B

Do NOT remove the lid before cooling liq-

uid drops below 50 °C (122 °F). Hot water
scald hazard.

• Remove plug. Let liquid flow out into the vessel of 11.5 l
(3 gal US) capacity.

374062C

• Check no hose pipes are damaged within engine’s cooling

system and no hose clips are missing. Inspect condition of
radiator whether it is not damaged, leaking, or whether ra-
diator’s plates are not clogged with dirt. Clean and repair it
if required.

144 AP 240
 MAINTENANCE MANUAL
Flush the system:
• Follow Engine Operation and Maintenance Manual to flush
the system during replacement, using mixture of water and
soda (sodium carbonate) in the ratio of 0.5 kg (1.1 lb) of soda
per 23 l (6.0 gal US) of water. Fill up the system with such
mixture and warm up to 80 °C (176 °F) with the engine run-
ning – do NOT install pressure closure for equalizer tank.
Shut off the engine and drain water, fill with new water and
warm up the engine, d drain water again. Repeat this until
water is clean.

• Fill cooling system with new cooling liquid in the ratio of

50 % water + 50 % antifreeze agent between MIN and MAX.
Max. filling speed is 10 l/min (2.6 gal US per minute). Use the
lid to close equalizer tank.

• Start the engine and wait until temperature reaches 80 °C

(176 °F). Then stop the engine. At the same time check that
no cooling liquid is leaking. Check level in equalizer tank,
make up to MAX.

Before filling up, let temperature drop be-

low 50 °C (122 °F). When plug is opened 374081
there is hazard liquid will splash out fol-
lowed by scald hazard.
Follow anti-freeze producer’s instructions
when exchanging anti-freeze!

Use anti-freeze according to Section

3.2.3.!

Drain liquid into collection vessel!

Hand over spent liquid for safe disposal in
line with regulations!

AP 240 145
3.6. Lubrication and Maintenance Operations
3.6.42. Compressor check

First carry out after 50 hours. 2

3
• Following first 50 hours, please tighten the bolts for com-
pressor head in such sequence as per the Fig. using 4
30÷33 Nm (22÷24.5 lb ft) torque. Perform this on the cold
engine after the machine has been stopped. 1

374043

• Delivery air piping (1) must have no pressure. Slacken bolt-

ing (2). Drain pressure air from the system.
• Remove delivery air piping (1) away from compressor. 2
1

374063A

• When the overall extent of carbon deposited on the wall ex-

ceeds the value of X+X=2 mm (1/16 in), you must clean or

OK
replace delivery pipe leading from compressor, and please
contact your dealer to carry out overall inspection and re-
pair of the compressor.

X
X

374N143

146 AP 240
 MAINTENANCE MANUAL
3.6.43. Air conditioning system check

• Have the functional check of individual components, wiring

checking, and air conditioning system cleaning (removal of
mould and bacteria) performed by an authorised company.
• In case of work in a highly dusty environment, have the
check performed in shorter intervals.

AP 240 147
3.6. Lubrication and Maintenance Operations

Maintenance if required

3.6.44. Water from separator draining

• Alarm signal from yellow pilot lamp.

396034

• Code No. 97 VODA V PALIVU will be displayed (WATER IN

FUEL).
1 of 1 WARNING
SPN 97 FMI 0
WATER IN FUEL DETECTED

HIDE

396286

• Drain water from separator.

374080A
Do NOT smoke while at work.
Do NOT drain separator while engine is
hot and running.

Collect drained fuel incl. sediment into a

proper vessel.

! CAUTION !
If you drained more than 60 cm3 (0.63 quarts) of fuel,
please fill up fuel in fuel filter according to the next
Section called “Deaeration”.

148 AP 240
 MAINTENANCE MANUAL
3.6.45. Fuel system venting

Deaerate fuel system before first starting:

• With fuel filters not filled with fuel – when replacing the fil-
ters
• During fuel pump replacement
• Upon long term shutdown of the Machine
• With fuel pumped out from the tank

Deaerate the filters:

• Slacken air relief screw (1) at fuel pre cleaner. Pump the fuel 1
via delivery pump (2) until it flow out clean, with no air bub-
bles, tighten the screw.
2

374080B

• Deaerate second filter via air relief screw.

374079A

Do NOT deaerate while engine is hot,

leaking fuel may cause fire.
Do NOT smoke!

Collect leaking fuel!

AP 240 149
3.6. Lubrication and Maintenance Operations
3.6.46. Coolers cleaning

• With regard to the Machine operating in various working

environments no regular interval for cleaning can be deter-
mined. When working in very dusty environment, carry out
cleaning on daily basis. Fouled radiator will cause increased
temperature of engine cooling liquid and hydraulic system
oil. Clean with pressure air or pressure water (steam) from
the side of cooling air blower.

374047A

Do NOT use cleaners with too high pres-

sure so to avoid any damage to radiators’
plates.
With radiator contaminated with crude oil
products (oil), use cleaning agent and pro-
ceed in line with producer’s instructions!
Find out the cause of contamination!

When cleaning, please proceed according

to ecological standards and regulations!
Perform cleaning at workplaces equipped
with cleaning agent collection system to
avoid any contamination of soil and water
resources!
NEVER use banned cleaning agents!

150 AP 240
 MAINTENANCE MANUAL
3.6.47. Refilling the oil level in the front axle
hydraulic cylinders

• Shut down the machine on a flat and solid surface where

there is no potential natural hazard (landslides, possible flo-
oding, etc.).

• Remove the front axle cover.

435056

• Refill the hydraulic cylinders using a filler through the qu-

ick-coupling.

431072

• Refill hydraulic oil to the specified dimension according to

the figure. Perform the check on both piston rods and calcu-
late the arithmetic mean of both values.

435122

• Disconnect the filler and check the quick-coupling on the

machine for leaks.
• Reinstall the cover.
• If you overfill the hydraulic cylinders, relieve the front axle
by supporting the frame with a jack or by hanging it on a
crane.

430128

AP 240 151
3.6. Lubrication and Maintenance Operations
• Remove the quick-coupling on the pipe and push out exce-
ss oil by gradual slow lowering.

431072

Follow the fire-fighting measures!

Use only the oil recommended in Chapter
3.2.4.

152 AP 240
 MAINTENANCE MANUAL
3.6.48. Sprinkling filter cleaning

• Remove the filter, clean its strainer.

Drain sprinkling tank and system always

before ambient temperature lowers be-
low 0 °C (32 °F)!

374103

• Drain tank (1). Drain sprinkling pipes at the front and back
by slackening the nozzles (2).

2
1

374104

3.6.49. Brush scrapers cleaning

• Check condition of front brushes (1), rear brushes (2) – clean

them and repair them.

1
2
374120

AP 240 153
3.6. Lubrication and Maintenance Operations
3.6.50. Machine cleaning

• When the work is completed clean the Machine to get rid

of major dirt! Carry out overall cleaning on regular basis, at
least once per week. When working on cohesive soils, soil
cements and lime soil, carry out overall cleaning on daily ba-
sis. Pay attention to the function of scrapers!

Before pressure cleaning the Machine

with water or steam, please blind all the
ports into which a cleaner might pen-
etrate (e.g. engine inlet port, cabin’s
ventilation port, etc.). With the Machine
cleaned remove these blinds.
Disconnect master switch!
NEVER expose electric parts or insulation
material (alternator, electric connections,
etc.) to direct stream of pressure water or
steam, always cover these locations.
Carry out the work with the engine
stopped.
Follow producer’s instructions when us-
ing cleaning agents.
NEVER use aggressive or easily ignitable
cleaning agents (e.g. petrol and/or incen-
diary materials easy to ignite).

When cleaning, please proceed according

to ecological standards and regulations.
Perform cleaning at workplaces equipped
with cleaning agent collection system to
avoid any contamination of soil and water
resources.
Do NOT use forbidden cleaning agents.

154 AP 240
 MAINTENANCE MANUAL
3.6.51. Check of wheel nuts for tightening

First carry out after 50 hours.

• Check the wheel nuts for tightening to 400 Nm (295 lb ft).

374062D

3.6.52. Air collector inspection

• The air collector is a simple pressure vessel serving as a com-

pressed air reservoir for the brake circuit and additional sys-
tems of the machine.

Air collector inspection in operation, i.e.

tests and examinations are carried out in
specialised repair shops, no later than af-
ter five years and always when they were
suffered damage or the machine broke
down.
No modifications, weldings and heat treat-
ments are allowed on the air collector! 374202

• If the air collector passed prescribed tests, it is necessary

to stamp the air collector plate with the test date and the
name of the worker who carried out the test. The air collec-
tor test must be recorded in the after-repair delivery report
of the machine and in the service book delivered with the
machine. It is necessary to remove name plates from air col-
lectors, which were put out of service after a fault was de-
tected, and the air collectors must be destroyed to prevent
their further use

AP 240 155
3.6. Lubrication and Maintenance Operations
3.6.53. Charging of the battery
• Only use chargers with an appropriate rated voltage. Check
that the charger is strong enough to charge the battery not
too strong to charge with excessive current.
• Read and observe the operating manual of the charger
manufacturer.
• Check that the ventilation holes in the battery cover are not
dirty or clogged and that gases can escape freely.
• Connect the positive terminal (+) of the battery to the posi-
tive terminal of the charger.
• Connect the negative terminal (-) of the battery to the nega-
tive terminal of the charger.
• Turn on the charger only after connecting the battery.
• Charge the battery with current corresponding to one tenth
of the battery capacity.
• After charging, first turn off the charger and then disconnect
the cables from the battery.
• The battery is fully charged, if:
- electric current and voltage remain constant in the case
of voltage-controlled chargers,
- the charging voltage in the case of current-controlled
chargers does not increase within two hours, the au-
tomatic charger turns off or switches to maintaining
charge.
156
Use rubber gloves and eye protection devices when han-
dling the battery.
Use suitable clothing to protect your skin against con-
tact with the electrolyte.
After eye contact with the battery electrolyte, immedi-
ately flush the affected eye thoroughly with running wa-
ter for several minutes. Then seek medical advice.
After ingestion of the electrolyte drink large quantities
of milk, water or suspension of magnesium hydroxide in
water.
In case of skin contact with electrolyte, remove your
clothing and shoes, wash the affected skin immediately
with soap and water or with solution of water and soda.
Then seek medical advice.
Do not eat, drink and smoke while working!
After completing the work, wash your hands and face
thoroughly with water and soap!
Do not check that a wire is live by touching the machine
frame.
When working with the battery always follow instruc-
tions of the battery manufacturer!
Never charge a frozen battery or battery with a tempera-
ture above 45 °C.
Stop charging if the battery is hot or leaking acid.
Check that the ventilation holes in the battery cover are
not dirty or clogged and that gases can escape freely. If
the ventilation holes are clogged, gases can accumulate
inside the battery and irreversibly damage it.
Never make direct conductive connection between both
poles of the battery to avoid a short circuit and a risk of
explosion of the battery.
Do not turn the battery upside down, the electrolyte can
flow out.
If the electrolyte is spilled, wash the affected area with
water and neutralize with lime.
Hand over the old inoperative battery for disposal.
AP 240
 MAINTENANCE MANUAL
3.6.54. Screw connection tightening check

• Check no main bolt connections (wheel nuts, axle mount, hydraulic connection mount, engine mount, mount of units attached to
the engine) have been slackened). Use torque spanners to tighten these.

TORQUE TORQUE
For 8.8 (8G) bolts For 10.9 (10K) bolts For 8.8 (8G) bolts For 10.9 (10K) bolts
Thread Nm lb ft Nm lb ft Thread Nm lb ft Nm lb ft
M6 10 7.4 14 10.3 M18x1.5 220 162.2 312 230.1
M8 24 25.0 34 25.0 M20 390 287.6 550 405.6
M8x1 19 14.0 27 19.9 M20x1.5 312 230.1 440 324.5
M10 48 35.4 67 49.4 M22 530 390.9 745 549.4
M10x1.25 38 28.0 54 39.8 M22x1.5 425 313.4 590 435.1
M12 83 61.2 117 86.2 M24 675 497.8 950 700.6
M12x1.25 66 48.7 94 69.3 M24x2 540 398.2 760 560.5
M14 132 97.3 185 136.4 M27 995 733.8 1400 1032.5
M14x1.5 106 78.2 148 109.1 M27x2 795 586.3 1120 826.0
M16 200 147.5 285 210.2 M30 1350 995.7 1900 1401.3
M16x1.5 160 118.0 228 168.1 M30x2 1080 796.5 1520 1121.0
M18 275 202.8 390 287.6

The values given in the Table are torques at dry thread (at coefficient of friction = 0.14). These values DO NOT apply to greased thread.

Chart for torques of cap nuts with “O” sealing ring - hoses

Torques of cap nuts with “O“ ring - hoses

Nm lb ft
Spanner
Thread Pipe Nominal Min Max Nominal Min Max
size
14 12x1.5 6 20 15 25 15 11 18
17 14x1.5 8 38 30 45 28 22 33
8
19 16x1.5 45 38 52 33 28 38
10
10
22 18x1.5 51 43 58 38 32 43
12
24 20x1.5 12 58 50 65 43 37 48
14
27 22x1.5 74 60 88 55 44 65
15
30 24x1.5 16 74 60 88 55 44 65
32 26x1.5 18 105 85 125 77 63 92
20
36 30x2 135 115 155 100 85 114
22
41 25
36x2 166 140 192 122 103 142
46 28
50 42x2 30 240 210 270 177 155 199
45x2 35 290 255 325 214 188 240
50 38
52x2 330 280 380 243 207 280
42

AP 240 157
3.6. Lubrication and Maintenance Operations
Chart for torques of necks with sealing edge or with flat Chart for torques of plugs with flat gasket
gasket

Neck Torques Plug Torques

G -M Nm lb ft G -M Nm lb ft
G 1/8 25 18 G 1/8 15 11
G 1/4 40 30 G 1/4 33 24
G 3/8 95 70 G 3/8 70 52
G 1/2 130 96 G 1/2 90 66
G 3/4 250 184 G 3/4 150 111
G1 400 295 G1 220 162
G 11/4 600 443 G 11/4 600 443
G 11/2 800 590 G 11/2 800 590

10 x 1 25 18 10 x 1 13 10
12 x 1.5 30 22 12 x 1.5 30 22
14 x 1.5 50 37 14 x 1.5 40 30
16 x 1.5 60 44 16 x 1.5 60 44
18 x 1.5 60 44 18 x 1.5 70 52
20 x 1.5 140 103 20 x 1.5 90 66
22 x 1.5 140 103 22 x 1.5 100 74
26 x1.5 220 162 26 x1.5 120 89
27 x 1.5 250 184 27 x 1.5 150 111
33 x 1.5 400 295 33 x 1.5 250 184
42 x 1.5 600 443 42 x 1.5 400 295
48 x 1.5 800 590 48 x 1.5 500 369

M-G
M-G M-G

282N221T 282N222T

158 AP 240
3.7. Defects MAINTENANCE MANUAL

Usually, defects are caused by incorrect operation of the machine. Therefore, in case of any troubles read
again properly through the instructions given in the operation and maintenance manual for the ma-
chine and engine. If you cannot identify the cause, contact a service department of an authorised dealer
or the manufacturer.

Troubleshooting in hydraulic and electric systems requires knowledge of these systems; therefore a ser-
vice department of an authorised dealer or the manufacturer should be called to solve these problems.

AP 240 159
3.8. Annexes
3.8.1. Wiring Diagram

Legend:

A 1 Turn signal flasher P 1 Gear box thermometer

A 2 Electronics of steering switching version 102-1 P 2 Manometer of gearbox lubrication
A 3 Multifunctional display Murphy PV-101 Q 1 Battery disconnector
A 5 Telematic unit R 1,2 Engine pre-heating
B 1 Position sensor of the accelerator pedal R 3 Resistor
B 2 Gearbox temperature sensor S 1 Ignition box
B 3 Gearbox lubrication pressure gauge sensor S 2 Front headlamps switch
B 4 Fuel level float S 3 Rear headlamps switch
C 1 Noise suppressing filter S 4 Warning beacon switch (optional)
E 1 Instrument lighting S 5 Brake light pressure switch
E 2,3 Front parking lights S 8 Warning lights switch
E 4,5 Tail lights S 9 Turn signal light switch
E 6,7 Front headlamps S 11 Left controller
E 8,9 Rear headlamps S 12 Right controller
E 10 Warning beacon (optional) S 13 Hydraulic tank float switch
E 11,12 Cab lighting S 14 Emergency brake button
E 13,14 Brake lights S 15 Parking brake switch
E 15 – 17 Left turn signal lights S 16 Differential lock switch (optional)
E 18 - 20 Right turn signal lights S 17 Differential lock switching indication (optional)
E 21 Reversing light (optional) S 19 Brake fault pressure switch
F 1-21 Safety fuses S 20 Brake pressure switch
G 1 Battery S 21 Hydraulic oil filter pressure switch
G 2 Alternator S 22 Engine air filter pressure switch
H 1 Horn S 24 Hydraulic oil overheating switch
H 2 Reverse horn (optional) S 25 Windscreen wiper switch
H 3 Indicator lamp of turn signal lights S 26 Rear screen wiper switch
H 4 Neutral indicator lamp S 27 Windscreen washer double button
H 5 Right steering indicator lamp S 28 Sprinkling overpressure switch (part of the sprinkling
H 6 Left steering indicator lamp pump)
H 7 Indicator lamp for hydraulic oil level S 29 Sprinkling cycler
H 8 Engine pre-heating indicator lamp S 30 Fan selector switch
H 9 Battery charging indicator lamp S 32 Air-conditioning thermostat (optional)
H 10 Indicator lamp of brake fault S 33 Air-conditioning overpressure fuse (optional)
H 11 Acoustic signalization of brake fault S 34 Edge cutter double button (optional)
H 12 Brake indicator lamp V 1,2 Blocking diodes
H 13 Indicator lamp of clogged hydraulics filter X 1-33 Interconnection connectors (X1,11,24,32 and 33 are free)
H 14 Indicator lamp of clogged engine air filter X 34 Mounting socket
H 16 Indicator lamp of hydraulics overheating X 35,36 Engine connectors
H 17 Sprinkling indicator light X 37 Engine diagnostics connector
K 1-3 Auxiliary relay X 38-43 Connectors J1939
K 5-8 Auxiliary relay Y 1,2 Gear selecting valves electromagnets
K 11-13 Contactors Y 3 Forward travel valve electromagnet
M 1 Engine starter Y 4 Reverse travel valve electromagnet
M 2 Front wiper Y 5 Brake valve electromagnet
M 3 Rear wiper Y 6 Differential lock valve electromagnets (optional)
M 4 Front windscreen washer Y 7 Air-conditioning compressor electromagnetic coupling
(optional)
M 5 Rear windscreen washer
Y 8 Edge cutter-up valve electromagnet (optional)
M 6 Sprinkling pump engine
Y 9 Edge cutter-down valve electromagnet (optional)
M 7-9 Fans

160 AP 240
 MAINTENANCE MANUAL

M1
50

M
31
R1 K12 F19 30 K11
Engine glowing
125A

G1 Q1 F22
R2 K13 F20 12V 135Ah 15A
Engine glowing G2
125A L

G
F10
B IG
X35Engine connector

F21
80A
1 2 3 4
F9
30A

S1

X2:4

X2:3

X2:2

X2:1
X8:7 X19:1 30 15/54
Car radio

X45
X20:2 50a
Y F1
X9:1
Mounting lamp socket X34 5 2
X9:2 15A

K1
Instrument panel illumination E1
3 1

F5 S2
E2 X15:1 X3:1 6 2
Front outline lights 5A 8
E3 1 3
9 10
E4 X16:1 X5:1

Tail lights E5 X17:1

E6 X15:2 X3:2 F6
Front headlights E7 15A

S3 F2
E8 X16:2 X5:2 1 5
Rear headlights E9 X17:2 9 10 15A

S4 F3
Warning beacon E10 X20:3 X8:2 1 5
9 10 15A
X15:7,8

X16:6 E11 X21:1 X20:1 X8:1

Cab lighting X17:6

E12
P
S5 X3:3

X3:4

E13 X16:3 X5:3

Brake lights
E14 X17:3

E15 X15:4 X3:6

15A
F4
E16
S8 A1
E17 X16:4 X5:4 S9 2
6 CL
1 5 8
Direction lights 1
E18 H3 7 3 5 -31

10
E19 15:5 X3:7

E20 X17:4 X5:5

C1
H1 X15:3 X27:4 H4
Horn
X3:5 F7
X28:1

7.5A
X29:4
HORN

S12 S11
1 1
HORN

2 2
3 3
H A X29:3 X27:3 A H
C C
D X29:1 X27:1 D

VP N N VP
X26:1
R X28:3 X26:3 R
F X28:2 X26:2 F
X10:10
X10:4
X10:7
X10:3

X10:8
X10:2
X10:9
X10:1

R R
N N
F F
A2
PŘF
PŘR
PŘ2
PŘ1
LŘ1
LŘ2
LŘR
LŘF

X10:20 X10:19
IN N
MB
MC
MA
ME
PŘ
LŘ

+
-

H5
X10:14
X10:13

X10:17
X10:18

X10:15
X10:16

X10:5,6
X10:21,22,23,24

H6
Speed solenoid Y1 X5:6
Speed solenoid Y2 X5:7
Travel forward - solenoid Y3 X5:8
Travel backward - solenoid Y4 X5:9

Reversing alarm X17:8 X18:2 H2 X18:1 X17:7 X5:10

Reversing light E21

1 2 3 4 5 6 7 8

108097_1en

AP 240 161
3.8. Annexes
Wiring Diagram

Legend:

A 1 Turn signal flasher P 1 Gear box thermometer

A 2 Electronics of steering switching version 102-1 P 2 Manometer of gearbox lubrication
A 3 Multifunctional display Murphy PV-101 Q 1 Battery disconnector
A 5 Telematic unit R 1,2 Engine pre-heating
B 1 Position sensor of the accelerator pedal R 3 Resistor
B 2 Gearbox temperature sensor S 1 Ignition box
B 3 Gearbox lubrication pressure gauge sensor S 2 Front headlamps switch
B 4 Fuel level float S 3 Rear headlamps switch
C 1 Noise suppressing filter S 4 Warning beacon switch (optional)
E 1 Instrument lighting S 5 Brake light pressure switch
E 2,3 Front parking lights S 8 Warning lights switch
E 4,5 Tail lights S 9 Turn signal light switch
E 6,7 Front headlamps S 11 Left controller
E 8,9 Rear headlamps S 12 Right controller
E 10 Warning beacon (optional) S 13 Hydraulic tank float switch
E 11,12 Cab lighting S 14 Emergency brake button
E 13,14 Brake lights S 15 Parking brake switch
E 15 – 17 Left turn signal lights S 16 Differential lock switch (optional)
E 18 - 20 Right turn signal lights S 17 Differential lock switching indication (optional)
E 21 Reversing light (optional) S 19 Brake fault pressure switch
F 1-21 Safety fuses S 20 Brake pressure switch
G 1 Battery S 21 Hydraulic oil filter pressure switch
G 2 Alternator S 22 Engine air filter pressure switch
H 1 Horn S 24 Hydraulic oil overheating switch
H 2 Reverse horn (optional) S 25 Windscreen wiper switch
H 3 Indicator lamp of turn signal lights S 26 Rear screen wiper switch
H 4 Neutral indicator lamp S 27 Windscreen washer double button
H 5 Right steering indicator lamp S 28 Sprinkling overpressure switch (part of the sprinkling
H 6 Left steering indicator lamp pump)
H 7 Indicator lamp for hydraulic oil level S 29 Sprinkling cycler
H 8 Engine pre-heating indicator lamp S 30 Fan selector switch
H 9 Battery charging indicator lamp S 32 Air-conditioning thermostat (optional)
H 10 Indicator lamp of brake fault S 33 Air-conditioning overpressure fuse (optional)
H 11 Acoustic signalization of brake fault S 34 Edge cutter double button (optional)
H 12 Brake indicator lamp V 1,2 Blocking diodes
H 13 Indicator lamp of clogged hydraulics filter X 1-33 Interconnection connectors (X1,11,24,32 and 33 are free)
H 14 Indicator lamp of clogged engine air filter X 34 Mounting socket
H 16 Indicator lamp of hydraulics overheating X 35,36 Engine connectors
H 17 Sprinkling indicator light X 37 Engine diagnostics connector
K 1-3 Auxiliary relay X 38-43 Connectors J1939
K 5-8 Auxiliary relay Y 1,2 Gear selecting valves electromagnets
K 11-13 Contactors Y 3 Forward travel valve electromagnet
M 1 Engine starter Y 4 Reverse travel valve electromagnet
M 2 Front wiper Y 5 Brake valve electromagnet
M 3 Rear wiper Y 6 Differential lock valve electromagnets (optional)
M 4 Front windscreen washer Y 7 Air-conditioning compressor electromagnetic coupling
(optional)
M 5 Rear windscreen washer
Y 8 Edge cutter-up valve electromagnet (optional)
M 6 Sprinkling pump engine
Y 9 Edge cutter-down valve electromagnet (optional)
M 7-9 Fans

162 AP 240
 MAINTENANCE MANUAL

1 2 3 4 5 6 7 8

S13 X6:1 K3
Hydraulic oil level S14 F8
2 1
H7 5 3 2 1 7.5A
X4:1 4

Y5 X6:2 S15
Brake solenoid 7 5

2 6

S16
Y6.1 X6:3 1 5
Differential lock solenoids Y6.2 9 10

Differential lock switch

X25:2 S17 X25:1 X6:4

45 26

44

10k
R3
Engine connector
54
60
1 28
Accelerator position 6
B1 35
5 27

X36
1
X4:5 H8 F11
21 53
B2 5A
Gearbox temperature
X4:6 S P1
°C

B3 X6:5 S MPa P2
Gearbox lubrication pressure
H9
P S19 X4:7 H10
Brake failure
X9:4 H11 X9:3

Brake
P S20 X6:6 H12

Hydraulic oil filter

P
S21 X6:7 H13

Engine air filter

P
S22 X4:8 H14

Hydraulics overheating S24 X6:8 H16

1 1 11 Y
Service
socket

12
TELEMATIC

2 7
F17
A5
X41

3 6 2
A
X43

3 4
X44

B
A C A
X40

X38

B F A
G
diagnostic

B C
Engine

A A A A
socket

X37
C
X40

B B B B
C C C C
D F12
A A E B
B B 1A
X42

C C A
B
X39a

C
A3 A2
X39

A4 A1

B4 X7:1 A5 A3 A6
Fuel gauge
G
X22:1 X21:2,3 X8:3,4 F13
X22:4 X20:4,5 15A
7
Front wiper M2X22:2 5 S25
M

X22:3
3
1
X23:1 X21:6

Rear wiper M3X23:2 X21:4,5 X8:5,6,8

M

X21:7 X20:8,9

X23:3 X21:8
S26
1 5

Front windscreen washer M4 X21:10 S27

M

7 5
Rear windscreen washer M5 X21:11
M

4 8

108097_2en

AP 240 163
3.8. Annexes
Wiring Diagram

Legend:

A 1 Turn signal flasher P 1 Gear box thermometer

A 2 Electronics of steering switching version 102-1 P 2 Manometer of gearbox lubrication
A 3 Multifunctional display Murphy PV-101 Q 1 Battery disconnector
A 5 Telematic unit R 1,2 Engine pre-heating
B 1 Position sensor of the accelerator pedal R 3 Resistor
B 2 Gearbox temperature sensor S 1 Ignition box
B 3 Gearbox lubrication pressure gauge sensor S 2 Front headlamps switch
B 4 Fuel level float S 3 Rear headlamps switch
C 1 Noise suppressing filter S 4 Warning beacon switch (optional)
E 1 Instrument lighting S 5 Brake light pressure switch
E 2,3 Front parking lights S 8 Warning lights switch
E 4,5 Tail lights S 9 Turn signal light switch
E 6,7 Front headlamps S 11 Left controller
E 8,9 Rear headlamps S 12 Right controller
E 10 Warning beacon (optional) S 13 Hydraulic tank float switch
E 11,12 Cab lighting S 14 Emergency brake button
E 13,14 Brake lights S 15 Parking brake switch
E 15 – 17 Left turn signal lights S 16 Differential lock switch (optional)
E 18 - 20 Right turn signal lights S 17 Differential lock switching indication (optional)
E 21 Reversing light (optional) S 19 Brake fault pressure switch
F 1-21 Safety fuses S 20 Brake pressure switch
G 1 Battery S 21 Hydraulic oil filter pressure switch
G 2 Alternator S 22 Engine air filter pressure switch
H 1 Horn S 24 Hydraulic oil overheating switch
H 2 Reverse horn (optional) S 25 Windscreen wiper switch
H 3 Indicator lamp of turn signal lights S 26 Rear screen wiper switch
H 4 Neutral indicator lamp S 27 Windscreen washer double button
H 5 Right steering indicator lamp S 28 Sprinkling overpressure switch (part of the sprinkling
H 6 Left steering indicator lamp pump)
H 7 Indicator lamp for hydraulic oil level S 29 Sprinkling cycler
H 8 Engine pre-heating indicator lamp S 30 Fan selector switch
H 9 Battery charging indicator lamp S 32 Air-conditioning thermostat (optional)
H 10 Indicator lamp of brake fault S 33 Air-conditioning overpressure fuse (optional)
H 11 Acoustic signalization of brake fault S 34 Edge cutter double button (optional)
H 12 Brake indicator lamp V 1,2 Blocking diodes
H 13 Indicator lamp of clogged hydraulics filter X 1-33 Interconnection connectors (X1,11,24,32 and 33 are free)
H 14 Indicator lamp of clogged engine air filter X 34 Mounting socket
H 16 Indicator lamp of hydraulics overheating X 35,36 Engine connectors
H 17 Sprinkling indicator light X 37 Engine diagnostics connector
K 1-3 Auxiliary relay X 38-43 Connectors J1939
K 5-8 Auxiliary relay Y 1,2 Gear selecting valves electromagnets
K 11-13 Contactors Y 3 Forward travel valve electromagnet
M 1 Engine starter Y 4 Reverse travel valve electromagnet
M 2 Front wiper Y 5 Brake valve electromagnet
M 3 Rear wiper Y 6 Differential lock valve electromagnets (optional)
M 4 Front windscreen washer Y 7 Air-conditioning compressor electromagnetic coupling
(optional)
M 5 Rear windscreen washer
Y 8 Edge cutter-up valve electromagnet (optional)
M 6 Sprinkling pump engine
Y 9 Edge cutter-down valve electromagnet (optional)
M 7-9 Fans

164 AP 240
 MAINTENANCE MANUAL

4 8

X12:1 X7:2 F14

M6 X12:2 X7:3 OUT S29 10A

Sprinkling

M
H17
X14:1

X14:2
K5 X6:10 F15
5 3
Y
C M7 2 1
B3
S30 X13:1 25A

M
R A1
OR B4
K6 B5

Y 2 1 A3

Fans C M8 X14:4 5 3 A4

M
R A5
OR X13:3

Y K7
C M9 2 1

M
R
OR X14:3 5 3 X13:2 X6:11 F16
10A

Edge cutter - up Y8 X7:4

S34
7 3
Edge cutter - down Y9 X7:5 1

X4:11
F18
X5:11 Reserve

P S33 S32
K8

AUTOCLIMA
1 2
X113:1 5 3 X46:1 X45:1
A/C compressor clutch Y7
X46:4 X46:4
X113:4

108097_3en

AP 240 165
3.8. Annexes
3.8.2. Hydraulics Diagram
1 Steering pump
2 Compressor pump
3 Compressor hydromotor
4 Steering hydromotor
5 Edge cutter hydromotor
6 Servo-steering
7 Priority valve
8 Diaphragm-type accumulator
9 Safety valve
10 Non return valve
11 Logic valve
12 Edge cutter block
13 Combined cooler
14 Hydraulic tank
15 Suction strainer
16 Filter + element
17 Sensor for filter clogged
18 Bleeder valve
19 Level gauge
20 Oil gauge
21 Temperature switch 85±3 °C
22 Fast coupling filling-type
23 Fast coupling measuring-type
24 Fast coupling measuring-type

166 AP 240
 MAINTENANCE MANUAL

200 200

210 210 210 210

140 140

P LS T L R P LS T L R

Dn10

Dn10
6
80/40-200
Dn10 Dn10

Dn8 Dn8 4
Dn12

6 11 CF EF
24 5
0,9 mm

a
LS 7 9 8 12

Dn12
120 bar
P
22 23 3 A1 Dn8
Dn12

b
B1

A B

63/32-250
M 110

Dn8
130
1 Dn12
Dn12

Compressor P T
Engine P2
2400
i=1.0

18 M
Transmission

2300 210 sp/min

i=1.0

16 sp/min
23 T
Dn8
Dn12

b
Dn32 Dn12
b

19 2 17 5 bar
Dn19

10 13
Dn19

18 16
Dn32

1,2 bar

15 21 20
14 23

85˚C

100

211790B_en

AP 240 167
3.8. Annexes
3.8.3. Air Distribution
1 Compressor
2 Air drier
3 Air filter
4 Air tank 35 l
5 Cooler
6 Brake pedal
7 Diaphragm-type booster
8 Four-way valve
9 Two-way valve
10 Drain tap
11 Electric valve
12 Brake pressure gauge
13 Spring cylinder
14 Sensor for filter clogged
15 Pressure switch
16 Coupling T – measuring-type
17 Coupling T – measuring-type
18 Coupling T – measuring-type

Option: Central Tyre Inflation System

20 Control valve
21 Non return valve
22 Tyre pressure gauge
23 Rotary-type supply
24 Safety valve

Option: Differential lock control

27 Pneumatic distributor
28 Hydraulic cylinder

Option: Hand brake

29 Hand-operated valve

168 AP 240
 Dn9

AP 240
6
Dn9
6

Dn9
Dn9
2 17
9
7
16 4

Dn9

520 kPa
500±50 kPa

5 Dn6 Dn6

Dn18
Dn12
Dn12
10 15 12 15
1 21 3
Hydromotor

Dn19
18 ccm
11 18
2400

200 kPa
14 300 Dn6
RPM
8 13

Dn32
Dn12

62mbar
63/36/160 15
23 Dn6

3 1
200 kPa

Hand brake
control Dn6 Dn6 18
24

63/36/160
22 Dn6
Central tyre
inflation Dn12
system 29 27 28 11 13
23 2
Differential
lock control
Dn6
Dn6

1 3 2 3
22

Dn6
Dn12
4 1 5

Front axle
21 20

Dn6
Dn6
Dn12
Dn6
24 1 3

Dn9
2
Dn9

23
24

Rear axle

211548Aen
MAINTENANCE MANUAL

169
3.8. Annexes
3.8.4. Table of spare parts

Chapter Spare part Order number

Every 20 hours of operation (daily)

3.6.4. Belt 1287632

3.6.5. Dust valve 1-952454

Every 250 hours of operation (3 months)

3.6.15. Engine oil filter 4-9501000307

Every 500 hours of operation (6 months)

3.6.19. Fuel filter 4-9501000308

3.6.19. Fuel filter 1194061

3.6.21. Oil filter 4-9502000402

3.6.25. Air filter element 4-5358520127

3.6.25. Air filter element 4-5358520128

3.6.25. Dust valve 1-952454

3.6.26. Filter element 4-612104

3.6.26. Filter element 4-5351010189

3.6.27. Filter 4-16481

Every 1000 hours of operation (1 year)

3.6.32. Belt 4-6160120097

3.6.35. Filter element 4-5358060018

Every 2000 hours of operation (2 years)

3.6.38. Filter element 1276829

3.6.38. Suction strainer 4-5451050018

3.6.38. Sealing tape 4-5422250006

3.6.38. Temperature sensor 4-5503580053

3.6.38. Hydraulic unit 1251998/1255297

3.6.38. Insert 4-5358520154

170 AP 240
 MAINTENANCE MANUAL
Content of the set of filters after 500 operating hours (4-760016)

Chapter Spare part Number of parts Order number

3.6.15. Engine oil filter 1 4-9501000307

3.6.19. Fuel filter 1 4-9501000308

3.6.19. Fuel filter 1 1194061

3.6.21. Oil filter 1 4-9502000402

3.6.25. Air filter element 1 4-5358520127

3.6.25. Air filter element 1 4-5358520128

3.6.26. Filter element 1 4-612104

3.6.26. Filter element 2 4-5351010189

Content of the set of filters after 1000 operating hours (4-760135)

Chapter Spare part Number of parts Order number

3.6.15. Engine oil filter 1 4-9501000307

3.6.19. Fuel filter 1 4-9501000308

3.6.19. Fuel filter 1 1194061

3.6.21. Oil filter 1 4-9502000402

3.6.25. Air filter element 1 4-5358520127

3.6.25. Air filter element 1 4-5358520128

3.6.26. Filter element 1 4-612104

3.6.26. Filter element 2 4-5351010189

3.6.35. Filter element 1 4-5358060018

AP 240 171
3.8. Annexes
Content of the set of filters after 2000 operating hours (4-760136)

Chapter Spare part Number of parts Order number

3.6.15. Engine oil filter 1 4-9501000307

3.6.19. Fuel filter 1 4-9501000308

3.6.19. Fuel filter 1 1194061

3.6.21. Oil filter 1 4-9502000402

3.6.25. Air filter element 1 4-5358520127

3.6.25. Air filter element 1 4-5358520128

3.6.26. Filter element 1 4-612104

3.6.26. Filter element 2 4-5351010189

3.6.35. Filter element 1 4-5358060018

3.6.38. Filter element 1 1276829

3.6.38. Insert 1 4-5358520154

172 AP 240
 MAINTENANCE MANUAL

Notes

AP 240 173
3.8. Annexes

Notes

174 AP 240
 MAINTENANCE MANUAL

Notes

AP 240 175
3.8. Annexes

Notes

176 AP 240
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Materials and specification data are subject to change without notice.

Book ID: 4-P06000-EN | © Ammann Group